Cogeneration networks

ABSTRACT

The invention provides systems and methods for a network of cogenerations systems. In some cases, each system includes at least one cogeneration plant and at least one host facility, where the systems in the network are under the control of a common control system that optimizes a result for the network as a whole. In some cases, each cogeneration system in the network has an individual profile that is used by the control system for controlling that individual cogeneration system. In some cases, one or more of the cogeneration plants is assembled from a set of at least two modular transportable units where the modular units contain sensors that are configured to be ready for transmission of inputs to the common control system with little or no modification when the units are assembled into the final cogeneration plant and actuators or actuator systems that are configured to be ready for reception of outputs from the common control system with little or no modification when the units are assembled into the cogeneration plant.

CROSS-REFERENCE

This application is a continuation of U.S. patent application Ser. No.13/841,068, filed Mar. 15, 2013, which claims the benefit of U.S.Provisional Patent Application Ser. Nos. 61/685,738, filed Mar. 23,2012; 61/685,737, filed Mar. 23, 2012; 61/685,765, filed Mar. 23, 2012;61/685,740, filed Mar. 23, 2012; 61/667,848, filed Jul. 3, 2012; and61/667,832, filed Jul. 3, 2012, all of which applications areincorporated herein by reference.

BACKGROUND OF THE INVENTION

Cogeneration plants provide an economical and efficient source ofelectrical power and thermal energy to associated host facilities. Thereis a need for systems and methods to optimize the deployment andperformance of cogeneration plants.

SUMMARY OF THE INVENTION

Provided herein are methods, compositions, and apparatus related topower cogeneration.

An aspect of the invention provides a cogeneration system comprising (i)a cogeneration plant operably connected to a host facility that receivesa thermal and/or mechanical work product and, optionally, electricalpower from the cogeneration plant under an agreement with thecogeneration plant owner, wherein the cogeneration plant comprises aplurality of operably connected modular transportable units; and (ii) acontrol system operably connected to the cogeneration plant comprising(a) a receiver system for receiving inputs from a plurality of sourcesof input wherein the sources of input comprise input from sensors in oneor more of the modular units, inputs from the host facility, and inputsfrom indicators of market and/or other external conditions, (b) aprocessor system operably connected to the receiver system, configuredto process the inputs and determine outputs for modulating theactivities of a plurality of actuators or actuator systems in one ormore of the modular units to achieve a desired result in the operationof the cogeneration plant based on the inputs and on the agreement; and(c) a transmitter system operably connected to the processor system fortransmitting the outputs to the actuators or actuator systems. Incertain embodiments, the modular transportable units exist in a firstform that is a transportable form and second form that is an assembledform, and the first form and the second form are substantially the samefor at least two of the modular transportable units, and wherein thesensors and actuators do not require substantial modification to convertfrom the transportable form to the assembled form. In certainembodiments, the sensors comprise at least 2 sensors for sensing inputsselected from the group consisting of a HRSG exhaust temperature, asteam flow rate, a generator output, an exhaust temperature, a thermalproduct carrier outlet temperature, a thermal product carrier inlettemperature, a thermal product carrier outlet flow rate, a thermalproduct carrier inlet flow rate, and/or at least one of a NOx, NH3, SOx,CO, CO2, particulate, and O2 emission. In certain embodiments, thereceiver is configured to further receive at least 2 inputs indicatingat least two environmental conditions at or near the cogeneration plant,wherein the environmental conditions are selected from the groupconsisting of temperature, humidity, wind speed, wind direction, time ofday, and air pressure. In certain embodiments, the receiver isconfigured to further receive input indicating a desired futuremodulation in the conditions of the host facility, wherein the input isinputted from an interface for interaction between the system and anoperator of the host facility. In certain embodiments, the receiver isfurther configured to receive at least 2 inputs indicating a marketcondition wherein the market conditions are selected from the groupconsisting of a price for a fuel for the cogeneration plant, a price forelectrical energy exported from the cogeneration plant, a price forimported electrical energy to the cogeneration plant, a price for anincentive for the cogeneration plant, a price for a demand responseaction, a price for a thermal product produced by the cogenerationplant, a price for water, and a price for a variable maintenance price.In certain embodiments, the inputs from the host facility comprise anelectrical energy demand, a thermal product demand, a thermal productcarrier flow rate, an air temperature, a thermal product carriertemperature, a fan rate, a humidity, a set point for an air temperature,a set point for a thermal product carrier temperature, or anycombination thereof. In certain embodiments, the processing of step(ii)(b) comprises a forecast step comprising forecasting a future valueor range of values or a probability of a future value or range of valuesfor one or more conditions selected from the group consisting of a fuelprice, an electricity export price, an electricity import price, anambient environmental condition, an emissions limit, an incentive forthe cogeneration plant, a price for a demand response action, a pricefor a thermal product, a price for mechanical work product, a price forwater, an electrical demand from the host facility, a thermal productdemand from the host facility, and a mechanical product demand from thehost facility. In certain embodiments, the control system furthercomprises a data storage unit for storing a timing and/or a value for aresult that occurs after the change in the one or more outputs, andwherein the control system is configured to adjust the processing stepbased on one or more of the results stored in the data storage unit. Incertain embodiments, the actuators comprise at least 2 actuatorsselected from the group consisting of an actuator or actuator system forcontrolling a pre-cooler, an actuator or actuator system for controllinga turbine, an actuator or actuator system for controlling a heatrecovery steam generator, an actuator or actuator system for controllinga thermal product carrier producer, an actuator or actuator system forcontrolling a mechanical work product carrier producer, an actuator oractuator system for controlling a cooling tower, an actuator or actuatorsystem for controlling one or more distribution pumps, and, an actuatoror actuator system for controlling a thermal energy storage productproducer. In certain embodiments, the control system is at leastpartially Web-based. In certain embodiments, the invention provides acogeneration network comprising a plurality of cogeneration systems ofany of the previous embodiments. In certain embodiments, the modularunits comprise two or more of the following (i) a gas turbine module;(ii) a heat recovery steam generation (HRSG) module; (iii) arefrigeration module; (iv) a balance of plant module; (v) a coolingtower module; (vi) a stack module.

In another aspect, the invention provides a method for achieving adesired result during a time period for a modular cogeneration plantcomprising (i) receiving inputs from (a) a cogeneration plant, whereinthe cogeneration plant comprises a plurality of modular transportableunits; (b) a first facility to which the cogeneration plant is obligatedto provide electrical power under a first agreement and a secondfacility to which the cogeneration plant is obligated to provide athermal product under a second agreement and, optionally, a thirdfacility under which the cogeneration plant is obligated to provide amechanical work product under a third agreement, (c) indicators ofexpenses or potential expenses for the cogeneration plant, and (d)indicators of revenues or potential revenues for the cogeneration plant;(ii) determining an output to modulate the activity of an actuator inthe cogeneration plant, the first facility, the second facility, thethird facility, or any combination thereof, based on the inputs and onthe first agreement and the second agreement and the third agreement,wherein the output is determined to achieve a desired result in the timeperiod for the operation of the cogeneration plant; and (iii)transmitting the output to the actuator or actuator system to modulatethe activity of the actuator or actuator to approach the desired result;whereby the desired result for the cogeneration plant in the time periodis achieved. In certain embodiments, the inputs from the cogenerationplant are from sensors in the modular transportable units of thecogeneration plant, wherein the modular transportable units exist in atransportable form and in an assembled form, and wherein the sensors areconfigured to be fully operational in the assembled form with nosubstantial modification from the transportable form. In certainembodiments, the output is an output to an actuator or actuator systemin a modular transportable unit of the cogeneration plant, wherein themodular transportable units exist in a transportable form and in anassembled form, and wherein the actuator or actuator system isconfigured to be fully operational in the assembled form with nosubstantial modification from the transportable form. In certainembodiments, the inputs further comprise environmental data comprisesambient temperature, absolute pressure, relative pressure,precipitation, humidity, wind, time of day, or any combination thereof.In certain embodiments, at least two of the first facility, the secondfacility, and the third facility are the same facility. In certainembodiments, the facility is a refrigerated facility, a food and/orbeverage processing facility, a university, a pharmaceutical facility,an oil and/or gas production facility, an EOR facility, a LNG facility,a process industry facility such as a refining facility, an ethanolfacility, or a chemicals facility, a commercial building, a hospital, awaste water treatment facility, a landfill, or any combination thereof.In certain embodiments, the desired result is an optimum profit thecogeneration facility. In certain embodiments, the optimum profit is theprofit that contributes to maximizing a total profit for a networkcomprising a plurality of cogeneration plants, wherein the cogenerationplant is part of the network. In certain embodiments, the determining ofstep (ii) is modulated or not modulated based on a result of a pastdetermination for an output, or a plurality of results of a plurality ofdeterminations for an output or a plurality of outputs. In certainembodiments, the determining of step (ii) is modulated or not modulatedbased on an input or plurality of inputs from an operator of the firstfacility or the second facility. In certain embodiments, the input fromthe first facility comprises information about one or more aspects of aprocess electric load. In certain embodiments, the input from the secondfacility comprises one or more aspects of a process thermal load. Incertain embodiments, the inputs further comprise environmental dataselected from the group consisting of ambient temperature, absolutepressure, relative pressure, precipitation, humidity, wind, time of day,or any combination thereof. In certain embodiments, the actuator oractuator systems to which the output is transmitted, comprises one ormore actuators or actuator systems that control one or more of (i) atemperature within the cogeneration plant, the first facility, thesecond facility, or the third facility, (ii) a pressure within thecogeneration plant, the first facility, the second facility, or thethird facility, (iii) a flow of a raw material (iv) an exhaust flow (v)a waste flow (vi) a thermal product carrier flow (vii) an electricalpower flow (viii) a utility input, (ix) a supply input, (x) a state ofoperation of a first thermal product carrier producer, for example arefrigeration unit, (xi) a state of operation of a second thermalproduct carrier producer, for example a second refrigeration unit, (xii)a state of operation of a turbine, (xiii) a state of operation of aturbine precooler, (xiv) a state of operation of a duct burner (xv) astate of operation of a mechanical work product producer or (xvi) anycombination thereof. In certain embodiments, at least part of thedetermining of step (ii) is performed at a location that is remote fromthe cogeneration plant, the first facility, the second facility, and thethird facility, wherein the location is at least 5 miles from any of thecogeneration plant, the first facility, the second facility, or thethird facility. In certain embodiments, the input is received, theoutput is sent, or both, via an Internet connection.

In yet another aspect, the invention provides a cogeneration systemcomprising a cogeneration plant that is operably connected to a hostfacility to which the cogeneration plant provides a thermal and/ormechanical work product and electrical power at a host site under anagreement, wherein the cogeneration plant comprises (i) a set ofoperably connected modular transportable units that comprises (a) afirst modular transportable unit comprising a natural gas-fired turbinegenerator with a maximum power output of between 1 and 40 MW, (b) asecond modular transportable unit comprising a HRSG for utilizing theexhaust gases of the turbine to generate steam and further comprising anemissions control unit to control NOx emissions, operably connected tothe turbine, and (c) a third transportable unit comprising an exhauststack unit with integrated emissions monitoring for NOx, operablyconnected to the HRSG; wherein the modular transportable units exist ina transportable form that is suitable for transport on an ordinaryroadway and in an assembled form that is fixed at the host site, andwherein the first, second, and third modular transportable units eachcomprise at least one sensor and at least one actuator or actuatorsystem, wherein the sensors are configured to transmit inputs to acontrol system for controlling the cogeneration plant and the actuatorsare configured to receive an output from the control system, with nosubstantial modification from their configurations in the transportableunits to their configuration in the assembled units; and (ii) thecontrol system comprises (a) a receiver system that receives inputs fromthe sensors in the modular units, signals from sensors in the hostfacility, signals from ambient environmental sensors, inputs frommarkets for natural gas, inputs from power markets, inputs from forecastsystems that comprise a weather forecast system and a price forecastsystem, and inputs from an interface through which the operator of thehost facility may enter changes in upcoming conditions at the hostfacility; (b) a processing system operably connected to the receiversystem for processing the inputs and determining outputs for modulatingthe activities of a plurality of actuators or actuator systems in one ormore of the modular units, wherein the plurality of actuators oractuator systems comprises the actuator or actuator systems in thefirst, second, and third modular transportable units, to achieve adesired result in the operation of the cogeneration plant based on theinputs and on the agreement; and (c) a transmitter system operablyconnected to the processor system for transmitting the outputs to theactuators or actuator systems; wherein the control system is at leastpartially Web-based and is configured to learn from an outcome of one ormore previous outputs and adjust the determining of future outputs basedon the learning, or on an override of an output or a plurality ofoverrides of outputs by an operator of the host facility, or acombination thereof. In certain embodiments, the cogeneration plantfurther comprises a forth modular transportable unit comprising asteam-driven compression refrigeration unit, operably connected to theHRSG. In certain embodiments, the system further comprises a fifthmodular transportable unit comprising a cooling tower, operablyconnected to the refrigeration unit.

In a further aspect, the invention provides a method of manufacturing amodular cogeneration plant comprising (i) transporting a set comprisinga plurality of modular transportable units to a host site comprising ahost facility that requires a thermal product and/or a mechanical workproduct and, optionally, electrical power from the cogeneration plant,wherein (a) each of the modular transportable units contains one or morecomponents, or parts of one or more components, of the cogenerationplant, and the components comprise a generator, a heat transfer unit, anair intake unit, and an exhaust unit; (b) the modular transportableunits exist in a transportable form and an assembled form; and (c) atleast two of the modular transportable units comprise at least onesensor and at least one actuator or actuator system, wherein the sensorsare configured to transmit inputs to a control system for controllingthe cogeneration plant and the actuators are configured to receive anoutput from the control system, with no substantial modification fromtheir configurations in the transportable units to their configurationin the assembled units; and (ii) assembling the modules into a completecogeneration plant wherein the modules are operably connected to providea functioning cogeneration plant under the control of the controlsystem, wherein the cogeneration plant is configured to provide thethermal product and/or mechanical work product and, optionally,electrical power to the host facility under an agreement between aprovider of the cogeneration plant and a provider of the host facility.In certain embodiments, the control system is further configured toreceive inputs from the host facility and from external sources and todetermine outputs for the actuators to achieve a desired result for theoperation of the cogeneration plant over a period of time based on theinputs from the sensors, the host facility, and the external sources,and on the agreement. In certain embodiments, the set of modulartransportable units comprises at least 2 modular transportable units,wherein the modular transportable units are selected from the groupconsisting of a first module comprising an electrical generator; asecond module comprising a heat recovery steam generator (HRSG); a thirdmodule comprising an exhaust stack; a fourth module comprising acomponent of a cooling tower; a fifth module comprising one or morepumps; a sixth module comprising a thermal product carrier producer and,optionally, a seventh module comprising a mechanical work productproducer; wherein at least one of the modules is different from at leastone of the other modules In certain embodiments, the modulartransportable units comprise a total of at least 5 sensors to transmitinputs to the control system, wherein the sensors are configured totransmit the inputs with no substantial modification from theirconfigurations in the transportable units to their configurations in theassembled units and wherein the sensors comprise sensors for atemperature, one or more sensors for a pressure, one or more sensors fora volume, one or more sensors for a first or a second state of one ormore units that can exist in the first or the second state, one or moresensors for a power generation level, one or more electrical sensors,one or more acoustical sensors, one or more optical sensors, one or morechemical detection sensors, one or more pH sensors, one or moreelectrical potential sensors, or one or more current sensors, or anycombination thereof. In certain embodiments, the control system isfurther configured to receive an input from the host facility comprisingan electrical energy demand, a thermal product demand, a thermal productcarrier flow rate, an air temperature, a thermal product carriertemperature, a mechanical work product demand, a mechanical work productcarrier flow rate, a fan rate, a humidity, a set point for an airtemperature within the host facility, or a set point for a thermalproduct carrier temperature, or any combination thereof. In certainembodiments, the control system is further configured to receive inputsfrom external sources. In certain embodiments, the external sourcescomprise sources of information about one or more market conditionscomprising information of a price for a fuel for the cogeneration plant,a price for electrical energy exported from the cogeneration plant, aprice for imported electrical energy to the cogeneration plant, a pricefor an incentive for the cogeneration plants, a price for a thermaland/or mechanical work product produced by the cogeneration plant, aprice for water for the cogeneration plant, and/or a price for avariable maintenance contract for the cogeneration plant, or anycombination thereof. In certain embodiments, the external sourcescomprise sources of information about environmental conditionscomprising one or more of a temperature, a humidity, a wind speed, awind direction, a time of day, a day of the year, or an air pressure, orany combination thereof. In certain embodiments, the receiver isconfigured to further receive input indicating a desired futuremodulation in the conditions of the host facility, wherein the input isinputted from an interface for interaction between the system and anoperator of the host facility. In certain embodiments, the controlsystem is configured to determine a change or no change for one or moreof the outputs for one or more of the actuators based at least in parton a forecast step. In certain embodiments, the control system isconfigured to determine a forecast step, wherein the forecast stepforecasts a future value or range of values, or a probability of afuture value or range of values, for a fuel price, an electricity exportprice, an electricity import price, an ambient environmental condition,an emissions limit, an incentive for the cogeneration plant, a price fora thermal product, a price for water, an electrical demand from the hostfacility, a thermal product demand from the host facility, or acombination thereof. In certain embodiments, the control system isconfigured to adjust the determining of a change or no change in the oneor more outputs on one or more of outcomes from one or more past outputsto the cogeneration plant. In certain embodiments, the actuators oractuator systems comprise 1, 2, 3, 4, 5, 6, or 7 of an actuator oractuator system for controlling a pre-cooler, an actuator or actuatorsystem for controlling an electrical generator, e.g., a turbine, anactuator or actuator system for controlling a heat recovery steamgenerator, an actuator or actuator system for controlling a thermalproduct carrier producer, an actuator or actuator system for controllinga cooling tower, an actuator or actuator system for controlling one ormore distribution pumps, and, optionally, an actuator or actuator systemfor controlling a thermal energy storage product producer. In certainembodiments, the control system is at least partially Web-based.

Another aspect of the invention relates to a cogeneration networkcomprising (i) a plurality of cogeneration systems, wherein eachcogeneration system comprises a cogeneration plant operably connected toa host facility that receives a thermal product and/or mechanical workproduct and, optionally, electrical power from the cogeneration plant,and wherein at least one of the cogeneration plants comprises aplurality of operably connected modular transportable units; and (ii) acommon controller for optimizing the operation of the cogenerationnetwork that is operably connected to the plurality of cogenerationsystems wherein the common controller (a) receives inputs from aplurality of sensors in or near each of the plurality of cogenerationsystems; (b) processes the inputs to determine a plurality of outputs,and (c) transmits the outputs to a plurality of actuators in theplurality of cogeneration systems, whereby the operation of the networkof cogeneration systems is optimized. In certain embodiments, thenetwork comprises at least 2 cogeneration systems wherein at least oneof the cogeneration systems comprises a plurality of operably connectedmodular transportable units. In certain embodiments, the sensorscomprise sensors in the cogeneration plants, sensors in the hostfacilities, sensors for the environment at or near one or more of thecogeneration plants and/or host facilities, or sensors for operableconnections between one or more of the cogeneration plants and it hostfacility, or any combination thereof. In certain embodiments, thesensors for the environment at or near one or more of the cogenerationplants comprise sensors for temperature, humidity, wind speed, winddirection, time of day, day of the year, air pressure, or anycombination thereof. In certain embodiments, the common controllerfurther receives input from one or more of the host facilities in one ormore of the cogeneration systems, wherein the input comprises anelectrical energy demand, a thermal product demand, a thermal productcarrier flow rate, an air temperature, a thermal product carriertemperature, a fan rate, a humidity, a set point for an air temperature,a set point for a thermal product carrier temperature, or anycombination thereof. In certain embodiments, the common controllerfurther receives inputs from indicators of market conditions. In certainembodiments, the inputs of market conditions comprise inputs for localmarkets at the one or more cogeneration systems. In certain embodiments,the market conditions comprise 2 prices for a fuel for at least 2 of thecogeneration plants, 2 prices for electrical energy exported from for atleast 2 of the cogeneration plants, 2 prices for imported electricalenergy to at least 2 of the cogeneration plants, 2 prices for anincentive for at least 2 of the cogeneration plants, 2 prices for athermal product produced by for at least 2 of the cogeneration plants, 2prices for water for at least 2 of the cogeneration plants, or 2 pricesfor a variable maintenance price for at least 2 of the cogenerationplants, or any combination thereof. In certain embodiments, the commoncontroller receives inputs from at least 10 sensors, wherein the sensorsare located in at least 2 cogeneration systems. In certain embodiments,the modular transportable units exist in a first form that is atransportable form and second form that is an assembled form, andwherein the first form and the second form are substantially similar forat least two of the modular transportable units. In certain embodiments,the common controller further receives input indicating a desired futuremodulation in a condition of at least 1 host facility wherein the inputindicating the desired future modulation is inputted from an interfacefor interaction between the system and an operator of the host facility.In certain embodiments, the sensors in one or more of the cogenerationsystems comprise 2 or more sensors for sensing 2 or more of a boilerexhaust temperature, a steam flow rate, a generator output, an exhausttemperature, a thermal product carrier outlet temperature, a thermalproduct carrier inlet temperature, a thermal product carrier outlet flowrate, a thermal product carrier inlet flow rate, or at least one of aNOx, NH3, SOx, CO, CO2, particulates, or O2 emission; or any combinationthereof. In certain embodiments, the modular transportable units of oneof the cogeneration plants comprise at least 2 of a modulartransportable unit comprising an electrical generator, a modulartransportable unit comprising part or all of a heat recovery steamgenerator (HRSG), a modular transportable unit comprising part or all ofa thermal product carrier producer, a modular transportable unitcomprising part or all of a cooling tower, a modular transportable unitcomprising part or all an exhaust stack, or a modular transportable unitcomprising part or all a an air intake unit, or any combination thereof.In certain embodiments, the controller is configured so that theprocessing of step (ii)(b) may comprise a forecast step. In certainembodiments, the forecast step forecasts a future value or range ofvalues, or a probability of a future value or range of values, for afuel price, an electricity export price, an electricity import price, anambient environmental condition, an emissions limit, an incentive forthe cogeneration plant, a price for a demand response action, a pricefor a thermal product, a price for water, an electrical demand from ahost facility, a thermal product demand from a host facility, whereinthe future value or range of future values, or probability of a futurevalue or range of future values, is a value or range of values orprobability of a value or range of values for at least one of thecogeneration systems. In certain embodiments, the future value or rangeof values, or probability thereof, is a value or range of values, orprobability thereof for at least 2 of the cogeneration systems. Incertain embodiments, the controller is configured so that the processingstep may comprise determining a change in one or more set points for oneor more the actuators based at least in part on one or more of theforecast values or range of values. In certain embodiments, the commoncontroller further comprises a data storage unit for storing a value fora timing and/or result that occurs after the change in the one or moreset points. In certain embodiments, the controller is configured toadjust the processing step based on one or more of the results of aprevious output, such as a result stored in the data storage unit, toimprove the function of the network in the future. In certainembodiments, the optimization of the operation of the network optimizesthe profit of the network over a desired time period. In certainembodiments, the optimization of the operation of the network optimizesan energy efficiency of the network over a desired time period. Incertain embodiments, the actuators in a cogeneration plant of the systemcomprise an actuator or actuator system for controlling a pre-cooler, anactuator or actuator system for controlling a turbine, an actuator oractuator system for controlling a heat recovery steam generator, anactuator or actuator system for controlling a thermal product carrierproducer, an actuator or actuator system for controlling a mechanicalwork product carrier producer, an actuator or actuator system forcontrolling a cooling tower, an actuator or actuator system forcontrolling one or more distribution pumps, or optionally, an actuatoror actuator system for controlling a thermal energy storage productproducer, or any combination thereof. In certain embodiments, thecontroller is configured to transmit outputs to at least 6 actuatorsspread over at least 2 cogeneration systems. In certain embodiments, thecontroller comprises a subcontroller for utilizing a thermal productcarrier distribution system as a thermal storage system in at least oneof the host facilities to both distribute a thermal product carrier andto store thermal energy. In certain embodiments, the common controlleris at least partially Web-based. In certain embodiments, the controlleris configured to update software, control logic, business logic, and/oralgorithms remotely. In certain embodiments, the common controller isconfigured to implement network diagnostics for optimizing schedulingand/or management of planned and/or unplanned maintenance. In certainembodiments, the controller controls management of spare parts acrossstandardized modular plants within the network.

In another aspect, the invention provides a system comprising (i) afirst cogeneration plant that produces electrical power and a firstthermal product and/or a first mechanical work product, operablyconnected to a first facility that utilizes at least a portion of theelectrical power from the first cogeneration plant and to a secondfacility that utilizes at least a portion of the first thermal productand/or the first mechanical work product, wherein the first facility andthe second facility may be the same or different; (ii) a secondcogeneration plant that produces electrical power and a second thermalproduct and/or a second mechanical work product, operably connected to athird facility that utilizes at least a portion of the electrical powerfrom the second cogeneration plant and to a fourth facility thatutilizes at least a portion of the second thermal product and/or secondmechanical work product, wherein the third facility and the fourthfacility may be the same or different; and (iii) a control systemoperably connected to the first and second cogeneration plants and thefirst, second, third, and fourth facilities, wherein the control systemis configured to (a) receive inputs from the first and secondcogeneration plants, the first, second, third, and fourth facilities,and indicators of expenses or potential expenses for the first andsecond cogeneration plants, indicators of revenues or potential revenuesfor the first and second cogeneration plants, or for any combinationthereof; (b) calculate a setpoint for an actuator or actuator system inthe first cogeneration plant, the second cogeneration plant, the firstfacility, the second facility, the third facility, or the fourthfacility, or any combination thereof, wherein the setpoint is based onthe inputs, and is calculated to optimize a result for the first andsecond cogeneration plants in a time period; and (c) if the setpointcalculated in (ii) is different from the current setpoint for theactuator or actuator system, send output to the controller to modulatethe activity of the actuator or actuator system to approach thesetpoint. In certain embodiments, the desired result is an optimizedprofit for the first and second cogeneration plants. In certainembodiments, the desired result is an optimized energy efficiency forthe first and second cogeneration plants.

In another aspect, the invention provides a network of cogenerationsystems comprising a first cogeneration system and a second cogenerationsystem, wherein the first cogeneration system includes a firstcogeneration plant that includes a plurality of modular transportableunits that are operably connected and a first host facility thatreceives electric power, a thermal product, or a mechanical workproduct, or any combination thereof, from the first cogeneration plantunder a first agreement, and the second cogeneration system includes asecond cogeneration plant that includes a plurality of modulartransportable units that are operably connected and a second hostfacility that receives electric power, a thermal product, or amechanical work product, or any combination thereof, from the secondcogeneration plant under a second agreement, and a common controllerthat comprises a receiving system configured to receive inputs from aplurality of sensors in a plurality of the modular transportable unitsin the first cogeneration plant and the second cogeneration plant, fromthe host facilities, and from external sources, a processing systemconfigured to process the inputs to achieve an optimal operating resultfor the network while meeting an obligation in the first agreement andan obligation in the second agreement, and a transmitting systemconfigured to transmit a plurality of outputs to a plurality ofactuators or actuator systems in a plurality of the modulartransportable units in the first cogeneration plant and the secondcogeneration plant so as to achieve the optimal operating result for thenetwork. In certain embodiments, the optimum result is an optimum profitfor the network. In certain embodiments, the optimum result is anoptimum energy efficiency for the network or part of the network. Incertain embodiments, the modular transportable units exist in a firstform that is a transportable form and second form that is an assembledform, and wherein the first form and the second form are substantiallysimilar for at least two of the modular transportable units.

Other goals and advantages of the invention will be further appreciatedand understood when considered in conjunction with the followingdescription and accompanying drawings. While the following descriptionmay contain specific details describing particular embodiments of theinvention, this should not be construed as limitations to the scope ofthe invention but rather as an exemplification of preferableembodiments. For each aspect of the invention, many variations arepossible as suggested herein that are known to those of ordinary skillin the art. A variety of changes and modifications can be made withinthe scope of the invention without departing from the spirit thereof.

INCORPORATION BY REFERENCE

All publications, patents, and patent applications mentioned in thisspecification are herein incorporated by reference to the same extent asif each individual publication, patent, or patent application wasspecifically and individually indicated to be incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the invention are set forth with particularity inthe appended claims. A better understanding of the features andadvantages of the present invention will be obtained by reference to thefollowing detailed description that sets forth illustrative embodiments,in which the principles of the invention are utilized, and theaccompanying drawings of which:

FIG. 1 is a representative view of an exemplary embodiment of acogeneration plant assembled from modular transportable units.

FIG. 2 is a schematic diagram of an exemplary embodiment of a network ofcogeneration systems.

FIG. 3 is a schematic diagram of an exemplary cogeneration plant.

FIG. 4 is a schematic diagram of an exemplary overview of a controlsystem.

FIG. 5 is a diagram of levels of inputs and outputs and control for acontrol system for a cogeneration plant.

FIG. 6A is a schematic diagram of a general scheme for subsystemoptimization and machine control.

FIG. 6B is a schematic diagram of an exemplary scheme for subsystemoptimization and machine control.

FIG. 7 is an exemplary representation of plant sensor data points.

FIG. 8 is a schematic diagram of an exemplary cogeneration plant thatties into an existing facility to supply mechanical work product.

DETAILED DESCRIPTION OF THE INVENTION

The invention provides methods and systems related to cogenerationplants and systems, their manufacture, assembly, and use. Particularfeatures of various embodiments of the invention include one or more of:systems and methods related to cogeneration plants with fully integratedcontroller for optimizing performance where the plant is assembled frommodular transportable units; systems and methods for efficiently andrapidly meeting a particular customer need for such a unit; systems andmethods related to networks of cogeneration systems under control of acommon controller to optimize a performance and/or reliability of thenetwork, where the cogeneration systems may include one or morecogeneration plants assembled from modular transportable units; systemsand methods for optimizing a performance, e.g., a profit, or e.g. anenergy efficiency, of a cogeneration plant or network of cogenerationplants; systems and methods to provide highly efficient cogenerationplants or systems where the plants or systems operate in an environmentof varying electrical and/or thermal demand and/or mechanical workproduct demand; systems and methods for simultaneously distributing athermal product carrier and storing thermal energy, systems and methodsfor simultaneously distributing a mechanical work product and storingmechanical energy, and the use of such systems and methods to improvethe efficiency of a cogeneration plant or cogeneration system.

Before the present invention is described in greater detail, it is to beunderstood that this invention is not limited to particular embodimentsdescribed, as such may, of course, vary. It is also to be understoodthat the terminology used herein is for the purpose of describingparticular embodiments only, and is not intended to be limiting, sincethe scope of the present invention will be limited only by the appendedclaims.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimit of that range and any other stated or intervening value in thatstated range, is encompassed within the invention. The upper and lowerlimits of these smaller ranges may independently be included in thesmaller ranges and are also encompassed within the invention, subject toany specifically excluded limit in the stated range. Where the statedrange includes one or both of the limits, ranges excluding either orboth of those included limits are also included in the invention.

Certain ranges are presented herein with numerical values being precededby the term “about.” The term “about” is used herein to provide literalsupport for the exact number that it precedes, as well as a number thatis near to or approximately the number that the term precedes. Indetermining whether a number is near to or approximately a specificallyrecited number, the near or approximating unrecited number may be anumber which, in the context in which it is presented, provides thesubstantial equivalent of the specifically recited number.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Unless otherwise indicated orapparent from context, percentages given herein are w/w. Although anymethods and materials similar or equivalent to those described hereincan also be used in the practice or testing of the present invention,representative illustrative methods and materials are now described.

All publications and patents cited in this specification are hereinincorporated by reference as if each individual publication or patentwere specifically and individually indicated to be incorporated byreference and are incorporated herein by reference to disclose anddescribe the methods and/or materials in connection with which thepublications are cited. The citation of any publication is for itsdisclosure prior to the filing date and should not be construed as anadmission that the present invention is not entitled to antedate suchpublication by virtue of prior invention. Further, the dates ofpublication provided may be different from the actual publication dateswhich may need to be independently confirmed.

It is noted that, as used herein and in the appended claims, thesingular forms “a,” “an,” and “the” include plural references unless thecontext clearly dictates otherwise. It is further noted that the claimsmay be drafted to exclude any optional element. As such, this statementis intended to serve as antecedent basis for use of such exclusiveterminology as “solely,” “only” and the like in connection with therecitation of claim elements, or use of a “negative” limitation.

As will be apparent to those of skill in the art upon reading thisdisclosure, each of the individual embodiments described and illustratedherein has discrete components and features which may be readilyseparated from or combined with the features of any of the other severalembodiments without departing from the scope or spirit of the presentinvention. Any recited method can be carried out in the order of eventsrecited or in any other order which is logically possible.

I. Cogeneration Plants and Host Facilities

The systems and methods of the invention are related to cogenerationplants that are connected to one or more host facilities at a host site.A cogeneration plant with its associated host facility or facilities towhich it supplies electrical power and/or one or more thermal productsand/or one or more mechanical work products is a cogeneration system.The cogeneration plant generates electric power and one or more thermalproducts, which is typically chilling or heating that is carried betweenthe cogeneration plant and the facility by a heat transfer fluid such asa water product, e.g., hot water, steam, chilled water, or ice and/orone or more mechanical work products such as steam turbine drivencompression. As referred to herein, “thermal product carrier” is usedinterchangeably with a “heat transfer fluid.” Heat may be transferred toor from the heat transfer fluid in the cogeneration plant in a varietyof ways that are known in the art. A unit that transfers heat to or froma heat transfer fluid is in some cases referred to as a “thermal productproducer” or “thermal product carrier producer” herein. An example ofsuch a unit is a refrigeration unit. In certain embodiments thecogeneration plant produces ice as a product, such as food grade ice. Incertain embodiments, the cogeneration plant produces a mechanical workproduct, e.g., a compressed gas such as compressed air and/or acompressed refrigerant gas, for example, ammonia, that is supplied toone or more host facilities. In some of these embodiments the compressedgas, e.g., refrigerant gas, is used by the host facility inrefrigeration units in the host facility. The mechanical work productproducer may comprise one or more steam turbine driven gas compressorssuch as screw compressors or centrifugal compressors that produce acompressed gas. The compressed gas may be, e.g., a refrigerant such asammonia and optionally ties in to an existing or new externalrefrigeration system at the host facility; for example, the cogenerationplant receives low pressure refrigerant gas from the host via a lowpressure tie-in and returns high pressure refrigerant gas via a highpressure tie-in. The low pressure gas tie-in may be upstream of anexisting electric motor driven compressor system and the high pressuregas tie-in may be downstream of the existing electric motor drivencompressor system, and the resulting piping configuration mayeffectively bypass an existing compressor system. In such embodiments,the existing electric motor driven compressors may remain in place aspeaking units and/or standby purposes.

The one or more host facilities may be any facility that is operablyconnected to the cogeneration facility and uses one or more of theproduced electrical power and/or thermal and/or mechanical work product.In some cases a host facility will take only one or more thermalproducts from the cogeneration plant. In some cases a host facility willtake only electrical power from a cogeneration plant. In some cases ahost facility will take only mechanical work product from a cogenerationplant. In some cases a host facility will take both electrical power andone or more thermal and/or mechanical work products from thecogeneration plant. In some cases more than one host facility will takeeither electrical power, one or more thermal or mechanical workproducts, or any combination thereof, including electrical power,thermal product, and mechanical work product, from the cogenerationplant. It will be appreciated that a cogeneration plant can supply one,two, three, four, five, or more than five host facilities, and that eachhost facility may be supplied with some combination of one or more ofelectrical power, thermal product, and/or mechanical work product, andthat the combination supplied to each host facility, or the quantity ofeach product in the combination, may vary with time. Exemplary hostfacilities include industrial plants, chemical plants, schools,hospitals, refrigerated facilities such agricultural facilities, andsuch as refrigerated warehouses, refineries, data centers, and otherfacilities well-known in the art, such as other facilities as describedherein. In one embodiment, the host facility is an agricultural facilitywhere agricultural products are kept chilled (refrigerated) afterharvest, and other activities specific to the agricultural functions areperformed, e.g., packaging for shipping, processing of agriculturalproducts, and the like. The cogeneration plant may be under an agreementwith the host facility or facilities to set the amount of electricalpower and/or thermal product and/or mechanical work product that thecogeneration plant supplies to the host facility or facility undervarious conditions. The cogeneration plant often is also under anagreement with a utility to supply electrical power when it produceselectrical power in excess of the requirement of its one or more hostfacilities. In some cases the cogeneration plant may also be under anagreement with one or more thermal product users to supply an excessthermal product, such as ice, for example, food grade ice, to the user,where the use is not a host facility and does not have an agreement withthe cogeneration plant for a continuing supply of the thermal product.All of these relationships, and any other relationships with services ormarkets that the cogeneration plant has, such as maintenance, supply,supplies such as water or supplemental electrical power, are typicallygoverned by either an agreement or by access to a market, or both.

A cogeneration plant generally includes a prime mover (eg, a gasturbine) with a generator (together, a power generator), or fuel cells,and a heat exchanger (also referred to as a heat transfer unit herein)for heat recovery. It can also include a thermal product carrierproducer (sometimes referred to herein simply as a thermal productproducer), such as thermally activated cooling system, for example arefrigeration unit. In some cases a cogeneration plant also includes adehumidification system. The components are integrated into a singleunit with electrical and mechanical connections. The type of powergenerator typically determines what type of thermally activatedtechnologies can use the waste heat from the power generator.Cogeneration plants of embodiments of the invention may generate powerusing one or more microturbines, turbines, reciprocating engines,combustion turbines, back pressure steam turbines, condensing steamturbines, fuel cells, organic Rankine cycle units, solar thermal units,hybrid fossil/renewable units, or hybrid fossil/fossil units. In certainembodiments the power is generated in part or in whole in a turbine orturbines, such as one or more natural gas burning turbines operablyconnected to one or more electrical generators; in general a “turbine,”as that term is used herein, refers to a turbine and its electricalgenerator, unless otherwise indicated. Although for convenience certainembodiments of the invention are described herein as using natural gas,any suitable gas may be used as a fuel for a turbine, such as naturalgas, biogas, syngas, or other fuel gas. The excess thermal energy fromthe prime mover may be used in one or more components including a heatexchanger, a heat recovery steam generator (HRSG) a thermal productcarrier producer such as a refrigeration unit, e.g. a steam-drivencompression refrigeration unit or an absorption refrigeration unit, amechanical work product producer such as a steam turbine drivencompressor and the like, as are well-known in the art. Additionalthermal energy may be supplied by one or more burners that augment theheat from the prime mover, e.g., one or more duct burners that supplyheat to a HRSG by burning fuel from an auxiliary input, such as naturalgas duct burners. Other components can include dehumidificationcomponents, which may use solid and/or liquid dessicant. In addition,cooling towers, exhaust stacks, and pumps are generally components of acogeneration system. Fans may also be included.

Host facilities that may be supplied by a cogeneration plant or plantsof the invention include, in addition to any facilities describedherein, food and/or beverage processing facilities, universities,pharmaceutical facilities, oil and gas production facilities, e.g.,offshore platforms, enhanced oil recovery facilities, liquefied naturalgas facilities, process facilities, e.g., refining facilities, ethanolfacilities, chemical facilities, commercial buildings, hospitals, wastewater treatment plants, or landfills. In some cases the primary thermalproduct will be chilling, in some cases the primary thermal product willbe heating, e.g., steam, and in some cases a mix of thermal productswill be used, as will be apparent to those of skill in the art. In somecases, the mechanical work product will be compression of refrigerantsfor use in existing or external refrigeration units.

In certain embodiments of the invention, a cogeneration plant includesone or more gas turbine generators that generate electrical power, oneor more HRSG units (e.g., HRSG), optionally with one or more ductburners that burn fuel gas to augment heat from the exhaust gases of theturbine, one or more refrigeration units, e.g., steam-driven compressionrefrigeration units, pumps, one or more exhaust stacks that may includeemission monitoring equipment, one or more cooling towers, and one ormore air intake units. Emissions control components may be present inone or more components of the plant in one or more of the modules, e.g.equipment for NOx control integrated into the HRSG unit. An exemplaryembodiment is illustrated in FIG. 3, wherein a cogeneration plantincludes a gas turbine and generator, a precooler for cooling ambientair supplied to the turbine, one or more sources of supplemental heat tosupplement the heat from the exhaust of the turbine, one or more HRSGs,an emissions control system, a steam turbine, a refrigerant condenser, arefrigerant evaporator, a steam condenser, cooling towers, where thecomponents are operably connected as shown in FIG. 3. A control systemoperably linked to the cogeneration plant may supply smart controls,monitoring, diagnostics, predictive and/or learning capabilities, and/orinvoicing data.

II. Modularity

The cogeneration plants provided in various embodiments of the inventionmay be constructed partially or completely of modular transportableunits that contain one or more of the components of the cogenerationplant. These modular transportable units, also referred to as modules ormodular units herein, may be manufactured and/or stored at one or morecentralized locations and dispatched to the host site for thecogeneration plant, where they are assembled into part or all of thecogeneration plant, generally with little or no modification of theindividual units.

Modular Transportable Units Modular transportable units are well knownin the art and include the containerized shipping units that can betransported by truck, train, or ship. In certain embodiments, the entirefunctional portion of the cogeneration plant is constructed from modularunits that are built and/or stored in one or more centralizedfacilities, e.g., one, two, three, four, five, or more than fivefacilities, and/or rapidly built according to pre-packagedspecifications by a supplier, transported to the host site, andassembled into a complete cogeneration plant to provide the power andthermal product and/or mechanical work product needs of the hostfacility or facilities. Modular units are constrained only by themaximum size that is easily transported on normal roadways, trains, orships, in particular embodiments this will be the size of a standardcontainerized unit.

One or more components of a cogeneration plant, or segments of one orcomponents, is included in each modular transportable unit, and incertain embodiments the set of units dispatched to the cogeneration siteprovides a complete or substantially complete set of materials forrapidly and efficiently constructing a cogeneration plant suited to theneeds of the particular host facility or facilities at the site. Themodules and their components are compatible with little or nomodification. In certain embodiments for examples in embodiments oflarger systems, e.g., plants that are larger than about 15 MW, part ofthe plant may be supplied as modular transportable units and part of theplant may require onsite construction or fabrication due to the largersize. In all embodiments, however, a control system for the plant isfully integrated and prepackaged so that after the modules are assembledinto the plant, the control system is ready to operate the plant withoutneed for substantial, or any, modification to the control system or itssensors or actuators. The control system is described more fully below.

In certain embodiments, the modules are assembled at the host site toprovide a fixed cogeneration plant. The modules are transported, e.g. bytruck, and at the site the modular transportable units are removed fromthe wheeled base, e.g., by crane, forklift, or other suitable means, andassembled together. Thus, the units can be considered to have atransportable configuration, and an assembled configuration. In somecases, a modular transportable unit is used “as is” at the host site,i.e., in the same or substantially the same form in which it wastransported; thus the transportable and assembled configuration for themodule are the same, or in some cases substantially the same. The wallsand roof of the unit remain attached and the unit is connected to otherunits via one or more docking sites, which may be covered or otherwiseprotected during transportation, as needed, then exposed for assembly.These modules, and others that are more substantially modified inassembly, may be configured with one or more docking sites to allowconnection with other modules onsite with no substantial modification,i.e., the docking sites are configured so that operable connection tothe other modules in the system requires little or no modificationbeyond joining pipes, electrical connections and the like. In someembodiments, adaptor units are provided to serve as adaptors between adocking site on one module and a dock on another module; these adaptorsmay be used when one module is sized significantly differently fromanother, as can happen with module gradations as discussed below. Themodular units are compatible so that after onsite assembly thecogeneration plant is ready to go, i.e., “plug and play.” Other unitsmay require modification for use, such as removal of one or more walls,the roof, or all of the walls and roof. In some cases walls will beadded to the final assembled cogeneration plant so that equipment is notexposed, etc. These walls, such as tilt-up walls, may be transported tothe site, e.g. by truck, such as part of a modular transportable unit.

In a fixed configuration, the modular transportable units are fixed to abase, such as a concrete slab; the attachment may be reversible to allowunits to be swapped out for maintenance, repair, or replacement, butwhen assembled some or all of the units are no longer mobile withoutmodification, e.g., no longer are part of a trailer that includes awheeled assembly. In certain embodiments, the modules are fixed and maynot be easily removed. In certain embodiments, the modules may bereadily disassembled and moved to a new host facility site. In otherembodiments one or more of the modular transportable units may remain ina mobile state, e.g., as a wheeled trailer, that is attached to otherunits to complete the cogeneration plant. Some modular units may befixed while others remain mobile in a given plant.

A modular transportable unit can contain one or more of a the componentsof a cogeneration plant, such as one or more prime mover, electricalgenerator, heat transfer unit such as a heat recovery steam generator(HRSG), thermal product carrier producer, mechanical work productproducer, air intake unit, cooling tower unit, pumps, exhaust stack, andother components, as described more fully herein.

Alternatively, some components can be large enough that more than onemodular unit is required for their transport, such as multiple units totransport a cooling tower or set of towers, air intakes, and the like.

In addition, two or more modules may contain parts of two or morecomponents of a cogeneration plant, such that when the modules areconnected, the components are completed. For example, one module maycontain one section of a HRSG and one section of a refrigeration unit,and another module may contain the other sections, such that when themodules are connected on-site, the HRSG and the refrigeration unit arefunctional and complete.

Modular transportable units are partially or completely pre-assembledand/or available for rapid assembly based on pre-existing specificationsby a suitable vendor, so that when a particular customer places anorder, the suitable set of modular transportable units may be obtainedrapidly and efficiently without the need for custom design and assembly.

Modular units included in cogeneration packages can include part or allof: air intake unit, prime mover unit, generator unit, HRSG unit,thermal product carrier producing unit, pump unit, cooling towerunit(s), and stack unit.

Sensors and Actuators A cogeneration plant is under the control ofcontrol system, where the control system includes: a receiver system, aprocessor system, and a transmitter system. The receiver system receivesinputs from a number of sources, as described more fully herein; one ofthe sources of input is sensors located in the cogeneration plant, and,in certain embodiments, in conduits to the host facility or facilitiesand/or in the host facility or facilities themselves. The processorsystem determines outputs for the control system based, in part, on theinputs. The transmitter system of the control system transmits outputthat may include signals that result in the modulation of the activityof one or more actuators or actuator systems in the cogeneration plant,conduits, and/or host facility or facilities. It will be appreciatedthat the control system that receives inputs, determines necessaryactions, and sends outputs, may be partially or entirely removed fromthe cogeneration plant, e.g., Web-based or otherwise connected via theInternet. In certain embodiments some or all of the sensors andactuators that provide input and receive output from the control systemmay be wireless. Control systems of the invention are described morefully herein; this section describes the sensors and actuators oractuator systems that send inputs to the control system and receiveoutputs from the control system, respectively, as they are present inthe modular transportable units.

These components are generally not provided in a single modulartransportable unit. Rather, they are designed and constructed tointegrate into a system spread throughout the cogeneration plant, fromtheir various components in various modular transportable units inconnection with components of the cogeneration plant, so that once theplant is assembled they are connected and ready to send inputs andreceive outputs.

In some cases individual components, e.g., turbines, refrigerationunits, and the like, may be supplied by manufacturers with their ownsensors and/or actuators and control systems that are, e.g., set tomanufacturers' set points; these are used as is or their function orlogic is modified as necessary to allow seamless integration into thesystem as a whole and the most efficient operation according to thedesign of the system. In addition, certain operating systems presentlyused for one or more aspects of cogeneration plant control may bedesigned to receive input and send output to various components and setsof components; the control system of the invention may either“overlay”such operating systems, replace the system, or some combination thereof.

Sensors The various components included in the modular transportableunits contain sensors configured to send input to the control system; inaddition, sensors may be included that operate on or around the modulartransportable unit which may require some installation at a specificsite, e.g., sensors for environmental conditions at the site.

Sensors that may be included in one or more of the modular transportableunits may include sensors for temperature, flow rate, pressure, outputs,inputs, presence or concentration of one or more chemical species,electrical signals, or any other measurable quantity suitable fordetermining an operating condition in the cogeneration plant Somesensors may be supplied with a component by a supplier, such as one ormore sensors supplied with a turbine, or with a refrigeration unit,etc., and may be either used as supplied or modified as necessary to befully integratable into the final assembled plan, as described morefully herein. A sensor may provide simple on/off information orinformation over a continuum, e.g., a continuum of temperatures, orpressures, or flow rates, etc.

Flow rate sensors may include one or more sensors for a prime mover fuelflow rate, e.g., flow rate for natural gas to a natural gas turbine, athermal product carrier flow rate, such as an output rate for chilledwater from a refrigeration unit or an input rate of chilled water to arefrigeration unit, a steam flow rate, exhaust gas flow rates, and otherrates as known in the art. Temperature sensors may include one or moresensors for exhaust gas temperature, temperature in a heat exchangersuch as a HRSG exhaust temperature, ambient temperature sensors, and thelike. Output sensors may include generator output sensors, and the like.Chemical species/concentration sensors may include, e.g., pH sensors,salt sensors, or emission monitoring sensors, such as for NOx, SOx, CO,CO2, O2, and/or particulates. Some or all of the sensors may be suppliedor modified so as to provide wireless output to the control system, suchas wireless output to a Web-based control system. One or more of thesensors may be configured to be easily replaced or modified as moreefficient or more sensitive sensors are developed; in addition, themodular transportable units may be configured to have slots for one ormore additional sensors to be added as they become available or arerequired; for example, an emissions control system may have a sensor forNOx but be configured to also accommodate sensors for, e.g., SOx and/orparticulates as regulatory conditions demand.

In certain embodiments the modular transportable units of thecogeneration plant include at least 1, 2, 3, 4, 5, 7, 10, 15, 20, 25,30, 35, 40, 45, 50, or more than 50 sensors, for example, 2-20, or 2-50,or 4-20, or 4-50, or 5-200, or 5-100, or 5-50 sensors, or 10-200,10-100, or 10-50 sensors, or 30-500, 30-200, 30-100, or 30-50 sensors,or 50-500, 50-200, or 50-100 sensors, that are integrated into theparticular components of the modular transportable units and ready tosend output to the control system with little or no modification uponassembly of the modules. In certain embodiments, where the modulartransportable units include at least a gas turbine and generator, aHRSG, a refrigeration unit, and a stack, the modular transportable unitsinclude at least 2, 3, 4, 5, 6, 7, 8, or more than 8 of sensors forsensing one or more of a HRSG exhaust temperature, a steam flow rate, agenerator output, an exhaust temperature, a chilled water outlettemperature, a chilled water inlet temperature, a chilled water outletflow rate, a chilled water inlet flow rate, and at least one of a NOx,NH3, SOx, CO, CO2, particulates, and/or O2 concentration. In certainembodiments a modular transportable unit containing the turbine containsintegrated sensors for generator output and exhaust temperature, amodular unit for a refrigeration unit contains integrated sensors forchilled water outlet temperature, chilled water inlet temperature, andin some cases, chilled water outlet flow rate and/or chilled water inletflow rate. In certain embodiments, a modular transportable unit for aHRSG includes a sensor for a steam flow rate and a HRSG exhausttemperature.

In some cases one or more sensors are included to sense a level and/orflow rate of an emissions control substance, such as an ammonialevel/flow rate for controlling NOx emissions. In some cases one or moresensors are included to sense a level and/or flow rate for an additiveto be added to a thermal fluid, such as glycol added to chilled water todecrease the freezing temperature; sensors may also be included to senseglycol or other additive concentration in the thermal fluid, e.g.,chilled water, glycol temperature in to a refrigeration unit, glycoltemperature out from a refrigeration unit.

On/off sensors may include one or more sensors for precoolers, turbine,HRSG, refrigeration unit, cooling tower, thermal energy storage, and thelike.

In addition, sensors for one or more environmental conditions may beincluded with one or more of the modular transportable units, to be usedat or near the cogeneration facility to provide input to the controlsystem regarding ambient environmental conditions. Some or all of thesesensors may remain attached to its unit or may be detached from themodular transportable unit(s) when deployed for use. These includesensors for one or more of temperature, humidity, wind speed, winddirection, and air pressure. Thus in certain embodiments, one or moresensors are used for sensing 1, 2, 3, 4, 5, 6 conditions from the set ofconditions comprising temperature, humidity, wind speed, wind direction,and air pressure.

Other inputs regarding conditions at the cogeneration plant, at the oneor more host facilities, and regarding market and other conditions, areprovided to the control system as described elsewhere herein; howeverthese inputs do not necessarily arise at the sensors that are part ofthe components of the modular transportable units.

As noted, one or more of the sensors in the components included in themodular transportable units may be a sensor supplied by a manufacturerof the component. Such a sensor may be modified as necessary to make itssignal suitable to be received as an input for the control system whenthe component is integrated into the overall cogeneration plant. Suchmodification may include modification of the sensor itself, ormodification of the signal from the sensor, or both. The end result ofsuch modifications is that the modular transportable unit and itscomponents are ready for sending inputs to the control system that maybe used with the processing system of the control system, with little orno additional modification on-site

In an exemplary embodiment of a cogeneration plant that supplies athermal product, such as chilling where the vehicle for chilling is acooling fluid, e.g., chilled water, as well as electrical power, to oneor more host facilities, the cogeneration plant may include subsystemsthat include a natural gas compressor, an optional precooler, a naturalgas turbine generator, a HRSG such as a boiler, one or morerefrigeration units, optionally, one or more thermal energy storagesystems (TES), one or more cooling towers, and a cooling fluiddistribution system. Optionally, the system may also include amechanical work product unit, e.g., a steam turbine driven compressorsystem. See FIG. 7. Sensors that provide input to the control systemfrom the subsystem, and that may be included in modular transportableunits that are assembled into the cogeneration plant, include: 1) forthe fuel gas, e.g., natural gas, compressor (which may not be needed insystems where the pressure of fuel gas, e.g., natural gas, from thesupply system is adequate) subsystem input sensors include sensors forfuel gas, e.g., natural gas flowrate, fuel gas, e.g., natural gas inletpressure, fuel gas, e.g. natural gas inlet temperature, and compressorpower input, and subsystem output sensors include sensors for fuel gas,e.g., natural gas outlet pressure, fuel gas, e.g., natural gas outlettemperature, and fuel gas, e.g., natural gas flowrate; 2) for theoptional precooler, subsystem input sensors include sensors for inletair flowrate, inlet air temperature, inlet air pressure, inlet coolingfluid flowrate, inlet cooling fluid temperature, and inlet cooling fluidpressure, and subsystem output sensors include sensors for outlet airflowrate, outlet air temperature, outlet air pressure, outlet coolingfluid flowrate, outlet cooling fluid temperature, and outlet coolingfluid pressure; 3) for the turbine generator, subsystem input sensorsinclude sensors for inlet air flowrate, inlet air temperature, inlet airpressure, and natural gas flowrate, and subsystem output sensors includesensors for percent load, generator power output, exhaust flowrate,exhaust temperature, and exhaust pressure; 4) for the HRSG, subsysteminput sensors include sensors for inlet exhaust air flowrate, inletexhaust air temperature, inlet exhaust air pressure, inlet fuel gas,e.g., natural gas flowrate (for duct burner), inlet water flowrate,inlet water temperature, inlet ammonia flowrate (for NOx control), andsubsystem output sensors include sensors for steam flowrate, steampressure, steam temperature, outlet exhaust flowrate, outlet exhausttemperature, outlet exhaust pressure, outlet exhaust emissions(including one or more of NOx, NH3, CO2, CO, SOx, particulates, or O2);5) for the refrigeration unit or refrigeration units, subsystem inputsensors include sensors for steam flowrate, steam temperature, steampressure, inlet condenser temperature, inlet condenser water flowrate,inlet condenser water pressure, return cooling fluid temperature, returncooling fluid pressure, return cooling fluid flowrate, and subsystemoutput sensors include sensors for percent load, outlet condensertemperature, outlet condenser water flowrate, outlet condenser waterpressure, steam condensate temperature, steam condensate flowrate,outlet cooling fluid temperature, outlet cooling fluid pressure, andoutlet glycol flowrate; 6) for the optional thermal energy storage unit,the subsystem input sensors include sensors for operational mode(build/harvest), inlet cooling fluid temperature, inlet cooling fluidflowrate, and the subsystem output sensors include sensors for outletcooling fluid temperature and outlet cooling fluid flowrate; 7) for thecooling tower or cooling towers, the subsystem input sensors includesensors for operational mode (on/off), fan speed, inlet condenser waterflowrate, inlet condenser water temperature, water make-up flowrate,water make-up temperature, ambient air temperature, and wet bulbtemperature, and the subsystem output sensors include sensors forblowdown flowrate, blowdown conductivity, outlet condenser waterflowrate, outlet condenser water temperature, outlet condenser waterpressure, and power input; 8) for the cooling fluid distribution system,the subsystem input sensors include sensors for supply cooling fluidflowrate, supply cooling fluid temperature, supply cooling fluidpressure, and power input, and the subsystem output sensors includesensors for return cooling fluid flowrate, return cooling fluidtemperature, and return cooling fluid pressure.

For the system shown in FIG. 7, several points serve as places wherevariables may be controlled, e.g., by actuators or actuator systems.These are shown in bold in FIG. 7 and include fuel gas, e.g., naturalgas flowrate for the fuel gas, e.g., natural gas compressor, fuel gas,e.g., natural gas outlet pressure for the fuel gas, e.g., natural gascompressor; inlet air temperature, inlet cooling fluid flowrate, outletair temperature for the optional precooler; inlet air flowrate, fuelgas, e.g., natural gas flowrate, percent load, and generator poweroutput for the turbine/generator set; inlet fuel gas, e.g., natural gasflowrate, inlet water flowrate, inlet ammonia flowrate, and steampressure for the HRSG; steam flowrate, percent load, outlet coolingfluid temperature, and outlet glycol flowrate for the refrigeration unitor refrigeration units; operational mode (build/harvest), inlet coolingfluid temperature, inlet cooling fluid flowrate, and outlet coolingfluid temperature for the optional TES; operational mode (on/off), fanspeed, and blowdown flowrate for the cooling tower or towers. Actuatorsand actuator systems are discussed below; it will be apparent to one ofskill in the art what actuators or actuator systems would be necessaryor useful in accomplishing control of the controlled variables and suchactuators or actuator systems are included in the overall system, e.g.,as part of the modules of modular transportable units to be assembledinto the system.

Actuators and Actuator Systems The various components contained in themodular transportable units also contain one or more actuators oractuator systems for effecting any changes determined by the controlsystem for the operation of the cogeneration plant. These actuators mayinclude on/off actuators as well as actuators that operate over acontinuum. Actuators may include one or more of actuators to control aflow rate, e.g., via a valve, a pump, a fan, etc., actuators to controlan electrical signal, actuators to control mechanical systems, and thelike.

Actuators of the invention may include one or more of an actuator oractuator system for controlling a pre-cooler, an actuator or actuatorsystem for controlling a turbine, an actuator or actuator system forcontrolling a heat recovery steam generator, an actuator or actuatorsystem for controlling a thermal product carrier producer, an actuatoror actuator system for controlling a cooling tower, an actuator oractuator system for controlling one or more distribution pumps, and,optionally, an actuator or actuator system for controlling a thermalenergy storage product producer.

Some actuators may be supplied with a component by a supplier, and maybe either used as supplied or modified as necessary to be fullyintegratable into the final assembled plant. The actuators in themodules are configured such that once the modules are assembled into thefinal cogeneration plant, they are ready to receive an output signalfrom the control system and control their respective actuators oractuator systems such that the function of the particular component ismodulated according to the signal from the control system. Suchmodification may include modification of the actuator itself, ormodification of the signal to the actuator, or both. For example, anactuator or actuator system supplied by the manufacturer of a turbinemay not allow operation of the turbine below 50% of turbine capacity asa safeguard against exceeding emissions limits, but it may be determinedthat the turbine can be operated at levels below that limit withoutexceeding emissions limits The actuator or its controlling software maybe modified so that should the control system for the cogeneration plantsend an output calling for the turbine to be operated at below 50%, theactuator will respond with the appropriate action, and the modifiedactuator or controlling software will be included in the turbinesupplied in the modular transportable unit for the turbine so that onceat the cogeneration plant site and assembled the turbine can be operatedaccording to control system outputs with little or no furthermodification. The end result of such modifications is that the modulartransportable unit and its components are ready for receiving outputsfrom the control system that may be used to modulate the operation ofthe cogeneration plant to conform to the output of the control system,with little or no additional modification on-site. Some or all of theactuators or actuator systems may be supplied or modified so as toreceive wireless input from the control system, such as wireless inputfrom a Web-based control system.

In certain embodiments the modular transportable units of thecogeneration plant include at least 1, 2, 3, 4, 5, 7, 10, 15, 20, 25,30, 35, 40, 45, 50, or more than 50 actuators, for example, 1-10, or1-20, or 2-10, or 2-20, or 5-200, or 5-100, or 5-50 actuators, or10-200, 10-100, or 10-50 actuators, or 30-500, 30-200, 30-100, or 30-50actuators, or 50-500, 50-200, or 50-100 actuators, that are integratedinto the particular components of the modular transportable units andready to receive input from the control system and control theirrespective units with little or no modification upon assembly of themodules.

Sets of Modules The invention provides for the ability to bothmodularize and customize a cogeneration plant by using sets ofpre-assembled or pre-specified modules that allow the supplier of thecogeneration plant to mix-and-match various units of the sets to providea customized cogeneration plant for a particular site according to theneeds of one or more host facilities at the site as well as, in somecases, agreements with other entities, such as utilities, suppliers,etc. In certain embodiments, sets of modules are stored at one or morecentralized locations, and/or are rapidly available from suppliers,where the sets of modules provide building blocks for cogenerationplants of a variety of power and thermal product and/or mechanical workproduct configurations.

This allows for supplying the needs of various cogeneration sites andtheir associated host facilities, which will vary from site to site, interms of electrical power requirements, thermal product requirements,mechanical work product requirements, degree of expected fluctuations inthe requirements, local emissions controls, variations in the details ofthe supply agreement between the owner of the cogeneration plant and thehost facility or facilities, variations in agreements between the plantand local utilities and/or suppliers, and the like.

Sets of modules on hand at one or more centralized sites, or availablefor rapid manufacture, can include subsets of modules that includemembers that provide various functions variously sized. Individualmembers from two or more subsets are combined to form an individual setsuitable for a particular host site, and the set is transported to thehost site and assembled into a fully functional cogeneration plantsuitable for the host facility or host facilities at the site.

For example, one subset of modules may provide individual members anelectrical generator, such as a turbine generator, for example a naturalgas powered turbine generator. Different members of the subset may besized differently, and the sizes are graduated to provide a selection ofturbine capacities, so that the proper capacity for a particular sitemay be selected. Similar subsets may be used for cooling towers, exhauststacks, pumps, heat transfer units such as heat recovery steamgenerators, e.g., boilers, thermal product carrier producers, e.g.,refrigeration units, air intake units, and the like, where the membersof each subset are sized in different sizes, and where different membersof different subsets are compatible for assembly into a completecogeneration plant; in some cases, one or more modifiers or adaptors canbe used to match members of different subsets that are sizedsignificantly differently for a particular cogeneration plant. Themodules may be manufactured as individual members to be assembled into aset that is either part of, or, more typically, all of the cogenerationplant.

Depending on the needs of a particular host site or host sites, a givenpower unit can be combined with one or more heat transfer and/or thermalproduct carrier production and/or mechanical work product productionunits to supply the necessary thermal and/or mechanical work product(s)in combination with the necessary power for that particular site orsites. This can be determined by, e.g., one or more contractualagreements between the provider of the cogeneration unit and the hostsite facility or facilities. In addition, the provider of thecogeneration plant may modulate size and unit selection based on presentor projected future thermal product markets, present or projected futuremechanical work product markets, power markets, emissions controlregulation, and the like. As described herein, depending on theprojected market for various power and thermal combinations, modules maycontain one or more functional units of one or more sizes.

Modules may also contain submodules that can be switched out dependingon changing conditions or other variables at a given site or sites orimprovements in technology. For example, emissions control submodulesmay used for natural gas-fired turbine emissions that control for NOx,as part of the standard modules (since NOx is a regulated emission fromnatural gases in virtually every location) and additional modules may beavailable to be added to the appropriate module based on anticipatedadditional emissions controls in some areas, e.g., more stringentemissions controls in some areas may require the addition of emissionscontrol submodules in natural gas-fired systems for SOx and/orparticulates, as well as perhaps swapping out the existing NOx submodulefor a more efficient module based on more stringent NOx emissionscontrols.

Various module subset combinations correspond to various predictablesets needed for known or projected cogeneration needs, andpre-manufactured sets of modules can be maintained to allow quickturnaround when a customer order is placed, or the specifications forsuch modules can be stored and available for rapid manufacture.

In an exemplary embodiment, the module sets include a first subset for anatural gas-fired turbine generator, a second subset for air intake, athird subset for exhaust, a fourth subset for heat transfer units, e.g.,HRSGs, a fifth subset for thermal product carrier producers, e.g.refrigeration units, a sixth subset for cooling units, e.g., towers, anda seventh subset for pumps, and, optionally (or instead of the thermalproduct carrier producer) a subset for mechanical work productproducers. Some or all of the subsets may be used to assemble a set ofmodular transportable units to be used at a particular site. All setswill include members from the turbine, air intake, exhaust, pumps, andheat transfer subsets; some sets will also include members from thethermal product carrier producing and cooling subsets and/or membersfrom the mechanical work product producer subset.

The gas-fired turbine subset includes individual members that includetwo or more of a modular transportable unit containing a turbine ratedat between 0.1 and 1.0 MW, a modular transportable unit containing aturbine rated at between 1 and 2 MW, a modular transportable unitcontaining a turbine rated at between 2 and 5 MW, a modulartransportable unit containing a turbine rated at between 5 and 10 MW,and a modular transportable unit containing a turbine rated at between10 and 40 MW. It will be appreciated that if a turbine is supplied by asupplier it may be constrained to the size limit provided by thatsupplier, e.g., in the 1-2 MW range turbines are available rated at 1.2,1.5, 1.7 MW and the like, similarly in the 2-5 MW range, turbines areavailable at 2.9, 3.5, 4.6 MW and the like.

Some other subsets of the module set are sized mostly according to theturbine and will be included in any set, such as the air intake subsetand exhaust subset.

For example, the module set also includes a subset for air intake units,where the individual members of the subset are sized according to thesizes of the individual members of the gas turbine subset. These memberscould thus include one or more modular transportable units to provideair intake for a turbine between 0.1 and 1 MW, one or more modulartransportable units to provide air intake for a turbine between 1 and 2MW, one or more modular transportable units to provide air intake for aturbine between 2 and 5 MW, one or more modular transportable units toprovide air intake for a turbine between 5 and 10 MW, one or moremodular transportable units to provide air intake for a turbine between10 and 40 MW.

The module set also includes a subset for exhaust stack units, where theindividual members of the subset are sized according to the sizes of theindividual members of the gas turbine subset. These members could thusinclude one or more modular transportable units to provide exhaust stackcapacity for a turbine between 0.1 and 1 MW, one or more modulartransportable units to provide exhaust stack capacity for a turbinebetween 1 and 2 MW, one or more modular transportable units to provideexhaust stack capacity for a turbine between 2 and 5 MW, one or moremodular transportable units to exhaust stack capacity for a turbinebetween 5 and 10 MW, one or more modular transportable units to provideexhaust stack capacity for a turbine between 10 and 40 MW.

Other parts of the module set are sized to be ready to meet particularcustomer combinations of electric power and/or thermal product and/ormechanical work product needs, which will vary from site to site, bothin terms of the proportion of total turbine output that is needed forprojected electrical power vs. thermal product needs vs. mechanical workproduct needs, or any combination thereof, and the proportion of thermalproduct needs that will be carried by a heated thermal product carriervs. chilled thermal product carrier. Thus, there may be a subset withvariously sized modular units for heat transfer, such as HSRG units,e.g., boilers, and subsets with variously sized units for chilling,e.g., compression-type refrigeration units such as steam-drivencompression-type refrigeration units, and subsets for cooling towers,where the members of the subsets are sized to provide the desiredoptionality in terms of meeting expected customer needs. In a simplecase, a site will require electrical power and only steam, e.g., to heata facility and/or to supply thermal energy for a process. In such a casea member of the HRSG subset may be used but not a member of therefrigeration unit subset nor, perhaps, a member of the cooling towersubset. In a more complex case, a site may be have need for electricpower, heating, and chilling, and in that case the complete set ofmodular transportable units would include a turbine, HRSG, air intake,exhaust, refrigeration unit, and cooling modules.

Thus, other subsets of the set of modular transportable units may bemore variously sized than the turbine, air intake, and exhaust subsets.For example, in certain embodiments the set of modular transportableunits may include a subset of modular transportable units that contain aheat transfer unit, e.g., a HRSG, such as a HRSG. The members of thesubset are sized according to the anticipated thermal product needs ofvarious sites. In addition, for sets of modules to be assembled forsites requiring chilling, the set of modular transportable units mayinclude a subset of modular transportable units that contain one or morerefrigeration units, e.g., one or more steam-driven compressionrefrigeration units, and another subset of modular transportable unitsthat contain cooling towers to match cooling requirements for the steamand refrigerant condensers of the various refrigeration units. Thus incertain embodiments the set of modular transportable units include asubset of modular transportable units whose members include a modulartransportable unit for a steam-driven compression type refrigerationunit for producing between 60 and 600 tons of refrigeration, a modulartransportable unit for a steam-driven compression type refrigerationunit for producing between 600 and 1200 tons of refrigeration, a modulartransportable unit for a steam-driven compression type refrigerationunit for producing between 1200 and 3000 tons of refrigeration, and,optionally, a modular transportable unit for a steam-driven compressiontype refrigeration unit for producing between 3000 and 6000 tons ofrefrigeration and, optionally, a modular transportable unit for asteam-driven compression type refrigeration unit for producing between6000 and 24,000 tons of refrigeration, and, optionally, a modulartransportable unit for a steam-driven compression type refrigerationunit for producing between 24,000 and 48,000 tons of refrigeration.

The subset of modular transportable units that includes cooling towersis sized to match the refrigeration units in the subset of modulartransportable units that include a refrigeration unit, e.g., a modulartransportable unit(s) for a cooling tower(s) with sufficient coolingcapacity for a steam-driven compression type refrigeration unit forproducing between 60 and 600 tons of refrigeration, a modulartransportable unit(s) for a cooling tower(s) with sufficient coolingcapacity for a steam-driven compression type refrigeration unit forproducing between 600 and 1200 tons of refrigeration, a modulartransportable unit(s) for a cooling tower(s) with sufficient coolingcapacity for a steam-driven compression type refrigeration unit forproducing between 1200 and 3000 tons of refrigeration, and, optionally,a modular transportable unit(s) for a cooling tower(s) with sufficientcooling capacity for a steam-driven compression type refrigeration unitfor producing between 3000 and 6000 tons of refrigeration and,optionally, a modular transportable unit(s) for a cooling tower(s) withsufficient cooling capacity for a steam-driven compression typerefrigeration unit for producing between 6000 and 24,000 tons ofrefrigeration, and, optionally, a modular transportable unit(s) for acooling tower(s) with sufficient cooling capacity for a steam-drivencompression type refrigeration unit for producing between 24,000 and48,000 tons of refrigeration.

The set modular transportable units may also include a subset of modulartransportable units that contains pumps, where the members of the subsetare sized according to the various probable configurations of the othersubsets.

For smaller turbines, e.g., in the 0.1 to 1 MW range and in the 1-2 MWrange, or in the 2-5 MW range or even 5-10 MW range, individual modularunits that are member of a subset, e.g., a turbine subset, may alsoinclude components that are members of another subset, e.g., an HRSG(e.g., boiler) subset. The combining of components of one subset withanother into single modular transportable units is constrained by thesize of the container for the modular transportable unit, which must betransportable on commonly available transport modes such as roads andrailways, and by the types of units that can logically be packagedtogether given their connection, venting, intake, and other needs. Suchcombinations will be readily apparent to one of ordinary skill in theart. Exemplary combinations include the following: In certainembodiments a single mobile transportable unit may contain a turbine andan air inlet; or a turbine and a HRSG; or a turbine, air inlet, andHRSG; or a turbine, HRSG, and exhaust stack; or a refrigeration unit andpumps; or stack and emissions monitor; or HRSG and emissions control; orHRSG, emissions control, stack, and emissions monitoring; or a coolingtower and pumps; or air turbine, HRSG, emissions control, stack, andemissions monitoring. It will be appreciated that the foregoingcombinations are exemplary and that any suitable combination to allow amodule to be used at a certain type of host site is part of theinvention. The number and type of functions that are combined into asingle module depend on the sizing requirements of the assembled packageand its configuration.

A complete set of modules for a functioning cogeneration plant caninclude, in certain embodiments, 2, 3, 4, 5, 6, 7, 8, 9, 10, or morethan 10 modules, e.g., modules chosen from subsets of modules asdescribed herein. This set may be assembled from members of theappropriate subsets, using subset members of appropriate size for eachparticular function required at the cogeneration site. Such anarrangement allows the supplier of the cogeneration plant to respondclosely to customer needs but to efficiently, economically, and rapidlytransport and assemble the required plant.

In certain embodiments, the invention provides a set of modulartransportable units, where the set includes a first unit that contains aturbine, a second unit that include a HRSG, e.g., a boiler, a third unitthat includes a thermal product carrier producer, a fourth unit thatincludes air intake units, a fifth unit that includes cooling towerunit, a sixth unit that includes an exhaust stack, and a seventh unitthat includes pumps. In certain embodiments the invention provides a setof modular transportable units, where the set includes a first unit thatcontains a natural gas turbine, a second unit that include a HRSG, athird unit that includes a refrigeration unit, a fourth unit thatincludes air intake units, a fifth unit that includes cooling towerunit, a sixth unit that includes an exhaust stack, and a seventh unitthat includes pumps. In certain embodiments the invention provides a setof modular transportable units, where the set includes a first unit thatcontains a natural gas turbine, a second unit that include a HRSG, athird unit that includes a compression refrigeration unit, a fourth unitthat includes air intake units, a fifth unit that includes cooling towerunit, a sixth unit that includes an exhaust stack, and a seventh unitthat includes pumps. In certain embodiments the invention provides a setof modular transportable units, where the set includes a first unit thatcontains a natural gas turbine, a second unit that include a HRSG withexhaust emissions control equipment, a third unit that includes asteam-driven compression refrigeration unit, a fourth unit that includesair intake units, a fifth unit that includes cooling tower unit, a sixthunit that includes an exhaust stack with exhaust emissions monitoringfor at least NOx, and a seventh unit that includes pumps. In certainembodiments the first, second, third, fourth, fifth, sixth, and seventhmodular transportable units are different units. In certain embodimentsat least two of the modular transportable units are the same. In certainembodiments at least three of the modular transportable units are thesame. In certain embodiments at least four of the modular transportableunits are the same.

In certain embodiments the invention provides units, e.g., modularunits, to be combined for industrial and/or agricultural refrigerationapplications, for example, in applications where the air temperature tobe achieved is lower than 40, 39, 38, 37, 36, 35, 34, 33, or 32 degreesF. The modules include modules to provide a gas turbine, HRSG, one ormore steam turbines, and one or more refrigerant compressors (e.g. oneor more screw compressors, centrifugal compressors, or other type ofcompressor). In some embodiments, the units tie into the host facilityby tieing in to existing low pressure vapor refrigerant line upstream ofexisting compressors, e.g., electric motor driven compressors, andreturning to high pressure vapor refrigerant lines downstream ofexisting compressors, e.g., electric motor driven compressors, andupstream of existing refrigerant condenser cooling towers. For example,in certain embodiments the system may be used to bypass an existingrefrigeration unit or units. The units may remain operational for use asbackup to the system and/or for use in peak requirement situations. Anexample of embodiments of these types is shown in FIG. 8. In certainembodiments, the system boundaries may be extended to include lowpressure vapor accumulators, refrigerant condenser cooling towers and/orhigh pressure vapor receivers. Further, the expanded equipment may bemodularized and/or incorporated into other modules.

In certain embodiments, the invention provides modules configured toprovide a mechanical work product, such as a compressed gas, to a hostfacility, where the host facility may then use the compressed gas andreturn a product where the gas has been used, for example, to providechilling, back to the cogeneration plant. For example, the modules mayinclude one or more steam driven turbine compression systems forcompressing a refrigerant gas, such as ammonia gas, that can be used bythe host facility in a refrigeration system, then returned to thecogeneration plant. In these embodiments, the cogeneration plantsupplies the compressed gas instead of, or in addition to, a thermalproduct such as chilled water. One or more host facilities may besupplied with one or more combinations of compressed gas, thermalproduct such as chilled water, or both.

Modular Financial Packages In addition, the templates for one or moreaspects of financial packages available to potential host facilitycustomers may be partially or completely standardized. This allows aprovider of cogeneration services, e.g., a build-own-and-operateprovider, to easily and quickly offer a package of options to apotential customer who can then choose a combination suitable for theirparticular situation. In this sense, financial packages are alsomodularized and can be included as part of an overall cogenerationpackage by a provider.

In certain embodiments the invention provides systems and methodsrelated to a network that includes two or more cogeneration systems. Thesystems may be controlled by a common controller.

III. Control

Certain embodiments of the invention include systems and methods forcontrolling a cogeneration plant, e.g., to achieve an optimum result,such as a maximum profit, and/or maximal energy efficiency from thecogeneration plant. In certain embodiments a network of cogenerationplants is controlled by a common controller, e.g., to achieve an optimumresult such as a maximum profit and/or maximum energy efficiency fromthe network. As used herein, “control system” and “controller” aresynonymous. For convenience the control systems are often described asfor a single cogeneration plant but it is to be understood that suchdescriptions apply equally to cogeneration plants that are part of anetwork controlled by a common control system.

Control systems of the invention include a receiver system for receivinginputs, a processor operably connected to the receiver system fordetermining one or more outputs based at least in part on the inputs,and a transmitter system operably connected to the processor fortransmitting outputs. The control system receives inputs from thecogeneration plant and from other sources, as detailed below, and sendsoutput to at least the cogeneration plant and, in some cases, to otherdestinations.

At the level of the cogeneration plant itself, the control system mayoperate at one or more of five levels, or combination of levels: 1) atthe level of direct reception of input from sensors at various parts ofthe cogeneration plant and direct output to actuators or actuatorsystems at the cogeneration plant, where the outputs are based on theprocessing of the control system; 2) at the level of inputs fromsubsystems and/or outputs to subsystems where the outputs are based onthe processing of the control system; 3) at the level of inputs fromgroups of multiple subsystems and/or outputs to groups of multiplesubsystems, where the outputs are based on the processing of the controlsystem; 4) at the level of inputs from the entire cogeneration plantand/or outputs for the entire cogeneration plant, where the outputs arebased on processing of the control system; and/or 5) at the level ofinputs from a network of cogeneration systems and outputs to aparticular cogeneration plant or group of plants, based on theprocessing of the control system. An example of a general schemeembodying elements of levels 1)-4) is shown in FIG. 6A. An example of aspecific scheme embodying elements of levels 1)-4) is shown in FIG. 6B.A network of cogeneration plants is depicted in FIG. 2.

The first level of input, output, and control is specific to specificsensors and actuators or actuator systems, see, e.g., FIG. 6A showingdirect machine control and FIG. 6B showing an example of a precoolerunder direct control. This may be the case for a component system thatis built to the specifications of the supplier, e.g., modular designspecifications, for the overall cogeneration plant, where inputs fromthe sensors, and output to the actuators may all move to and from thecontrol system directly, with little or no intervening level ofprocessing. Sensors and/or actuators under direct control may be foundas well as in piping systems between subsystems, valves, conduitsbetween subsystems, electrical connections, and the like.

The second level of input, output, and control may be used forsubsystems, e.g., vendor-supplied subsystems where the subsystem issupplied with sensors, actuators or actuator systems, and, typically,some degree of control logic built-in, and the control system operatesat the level of the input from the sensors, input from processors, andother input as provided by the supplied subsystem, processes thesevalues to achieve subsystem optimization within the context of theoverall system, and sends output which is taken by the subsystem toimplement actuator or actuator system changes based on the built-inactuators and processing of the subsystem. This level of processing bythe control system can also occur for subsystems that are made tospecifications, e.g., modular design specification, for the overallcogeneration plant; in these cases some combination of direct controland subsystem control may be used, as appropriate for achieving anoptimal result. See, e.g., FIG. 6A Subsystem A and subsystem B,corresponding in FIG. 6B to a turbine and two HRSG units, respectively.

The third level of input, output, and control may take information frommultiple subsystems, multiple direct machine control modules, or acombination of subsystems and direct machine control modules, and sendappropriate outputs based on the processing of the control system, wherethe outputs may be directed toward direct machine control and/orsubsystem control, to optimize the operation of the multiple subsystemsand/or direct machine control modules. See FIG. 6A, multiple subsystemoptimization, and FIG. 6B, where an example is shown of optimization ofa precooler, turbine subsystem, and HRSG subsystem. Another example ofsuch multiple subsystem optimization may be, e.g., the optimization ofone or more refrigeration units, HRSGs, distribution pumps for chilledproduct carrier (i.e., heat transfer fluid such as a chilled waterproduct, e.g. a water/glycol mix) and, optionally, fans in a chilledfacility, to optimize the overall performance of the subsystem such asto keep the operation of the refrigeration unit as close to optimalefficiency as possible (see further description of thermal energydistribution and storage as described herein). These are of coursemerely exemplary embodiments and exact combinations will be determinedby sources of components (made to specification or supplied according tovendor specification), logical groupings of subsystems, and the like.

The fourth level will occur in the control system to optimizecombinations of any of the first three levels as may be required ordesired for a particular combination of, modular transportable units andtheir corresponding components for a cogeneration plant. The fourthlevel of control optimizes operation of the entire plant to produce adesired result, e.g., an optimum profit and/or an optimum energyefficiency for the plant.

The fifth level will occur for a cogeneration plant that is part of anetwork of cogeneration systems, where the control system achieves aresult for the network as w whole, such as an optimum profit for thenetwork or part of the network and/or an optimum energy efficiency forthe network or part of the network.

Combinations of input and output may be utilized that combine one ormore of the levels above, as appropriate to achieve control of thecogeneration plant while allowing the necessary components and controllogic to be such that little or no modification is required on assemblyof the plant in order for the control system to be functional to achievea desired result for the cogeneration plant. For example, direct inputmay be taken from a specific sensor, processed in a processing unit, andcomplex output may be sent to multiple subsystems. A specific example isa sensor senses and transmits to a processing system a singletemperature reading for the chilled water-glycol outlet from therefrigeration unit evaporator, the processing system determines a set ofactions required and the processor system sends outputs to therefrigeration unit, HRSG and turbine. This is merely exemplary and itwill be appreciated that any combination of inputs, processing, andoutputs from any of the five levels described may be used to achievecontrol of the cogeneration plant. Control functions such as this arehandled in the greater context of optimizing plant or network operation.

In all cases of control at any level, in embodiments in which one ormore modular units are used in the assembly of the cogeneration plant,the control system is configured so that, on assembly of the modules,little or no modification to the modules or aspects of the controlsystem is required for the control system to be fully capable ofoptimizing a result for the cogeneration plant. The necessary controllogic and, if necessary, hardware, is incorporated into the modules, sothat integrating any sensors, actuators, subsystems, multiplesubsystems, other control logic, and the entire system, may occurwithout the necessity for modifying components of the modules in asubstantial way, and on assembly of the modules into the finalcogeneration plant, the control system is ready to operate the plant toachieve a desired result. In certain embodiments, no modification of anycomponents in the modules is necessary. For example, where the modulescontain, e.g., a turbine supplied by a vendor where control is at thesubsystem level, the necessary control logic and, if necessary,hardware, for integrating the vendor product into the control system asa whole is already implemented and in place in the module and/or in thecontrol system. Similar considerations are true for the control ofmultiple subsystems, the system as a whole, and, in the case of a systemthat is part of a cogeneration network, the integration of the systeminto the network.

Part or all of the control system may be remote from the cogenerationplant or plants that it controls, e.g., Web-based. In some embodiments,part of the control system is at the cogeneration plant and part isremote. In some embodiments, the entire control system is remote. Ineither case, some or all of the inputs and/or outputs to and from thecontrol system may be transmitted wirelessly. It will be appreciatedthat partially or completely Web-based systems may be distributed overmany different areas. In certain embodiments, control system, e.g.Web-based control systems, allow for one or more of a remote update forpricing models, utility tariffs, demand response events, governmentincentives, software upgrades, algorithms and control modules, and/orpredictive databases. In certain embodiments, control system, e.g.Web-based control systems, allow for audit grade reporting for one ormore of: one or more of metering, virtual sub-metering,billing/invoicing, and/or account management.

An example of a scheme for a control system along with inputs andoutputs is given in FIG. 4, which shows a set point generator. In thisexample, the set point generator receives inputs for a facility thermaldemand load, such as a facility refrigeration load, a facility processelectric load, weather data, and optimization algorithms, as well ascogeneration plant sensor data, and facility sensor data.Manual/operator inputs and/or inputs from a network and systemperformance data, are processed by predictive models and/or learningmodules, to supply further input to the set point generator. Plantoperational unit costs and plant unit revenue are also input to the setpoint generator. The set point generator generates predicted valueswhich are further processed with performance monitoring and/ordiagnostics in a feedback loop back to the set point generator, whichoutputs sequenced set points. Further outputs from the control system asa whole can include meter data, real-time performance trends, metrics,and PPA invoicing, as well as alarms and predictive models and learningmodules. The set point generate utilizes mass and energy balance for allpossible scenarios, calculate, e.g., net profit for all possiblescenarios (in some embodiments, energy efficiency for all possiblescenarios, which may be combined with net profit or used alone), selectsan optimum scenario and generates predicted values and set points. Setpoints and feedback from the feedback loop are processed in an automaticreconfiguration and corrective action generator.

The exemplary set point generator of FIG. 4 may be considered oneembodiment of a control system of the invention. The set pointgenerator, predictive modules, learning modules, performance monitoringprocessing, and/or diagnostics monitoring shown in FIG. 4, in variouscombinations, are also embodiments of control systems of the invention.For example, in one embodiment, the invention provides a control systemfor controlling a cogeneration plant that include a set point generator,one or more predictive models, one or more learning modules, one or moreperformance monitoring modules, and one or more diagnostics modules,where the set point generator receives input indicating a facilitythermal product load, such as a facility refrigeration load, and/ormechanical work product load, a facility process load, weather data,and, optionally, optimization algorithms, and where the performancemodels and learning modules receive input from manual/operator inputsand, optionally, from a network for system and performance data forother cogeneration plants and facilities, and sends input to the setpoint generator, and where the set point generator further receivesinputs for cogeneration plant operational unit costs and cogenerationplant unit revenue, and from cogeneration plant sensors and facilitysensors, and where the set point generator sends outputs to theperformance monitoring module and the performance monitoring modulesends outputs to the diagnostics module, which sends input back to theset point generator, in a feedback loop, and where the set pointgenerator sends outputs of sequenced set points. The system of FIG. 4also illustrates a maintenance optimization embodiment in that thediagnostics module may compare monitored performance to predicted valuesand determine probable causes for discrepancies, which in turn may beeliminated or mitigate as desired by alterations in a maintenanceschedule or routine.

Inputs The control system may receive input from the cogeneration plantor plants that it controls, from the distribution system for itselectrical power and/or thermal products, and/or mechanical workproducts, from one or more host facilities associated with thecogeneration plant or plants, from the environment around thecogeneration plant or plants and/or the host facility or facilities, andfrom external sources such as databases and other indicators of marketconditions, weather, etc., and/or from any other suitable source.

In addition the control system may receive as input updates ormodifications to its programs, e.g., software updates, which maymodulate the control system function. These updates or modifications maybe received on average every 6 months to one year, or every one to 6months, or every one week to one month, or every one day to one week, oreven more often, e.g., an average of an update or modification every dayor less. In embodiments where the control system learns and modifies itsbehavior, some updates and modifications may be due to such learning. Ina control system for a network of cogeneration plants, the controlsystem may automatically update based on learning from any one orcombination of more than one of the cogeneration plants. This may be inthe form of automatic change of the program, or may come from a sourceoutside the control system, or both. Thus, for example, the controlsystem may receive update to algorithms via the Cloud (the Internet),without the need to physically modulate a control system at a particularcogeneration plant or even physically visit a particular cogenerationplant.

A control system of the invention may be configured to receive anynumber of suitable inputs in a given time period. For example, a controlsystem may be configured to receive at least 10, at least 20, at least50, at least 100, at least 200, at least 500, at least 1000, at least2000, at least 5000, or at least 10,000 inputs in a given time period,on average. The time period may be, e.g., a minute, 5 minute, 10minutes, 30 minutes, an hour, or a day. For example, in certainembodiments a control system of the invention is configured to receivean average of at least 100 inputs per 10 minute interval. In certainembodiments a control system of the invention is configured to receivean average of at least 500 inputs per 10 minute interval. In certainembodiments a control system of the invention is configured to receivean average of at least 1000 inputs per 10 minute interval.

Control systems that control a network of cogeneration plants may beconfigured to receive even more inputs in a given time period. Forexample, a control system that controls a network of cogeneration plantsmay be configured to receive at least 20, at least 50, at least 100, atleast 200, at least 500, at least 1000, at least 2000, at least 5000, atleast 10,000, or at least 20,000 inputs in a given time period, onaverage. The time period may be, e.g., a minute, 5 minute, 10 minutes,30 minutes, an hour, or a day. For example, in certain embodiments acontrol system of the invention for controlling a network ofcogeneration plants is configured receive an average of over 1000 inputsper 10 minute interval. In certain embodiments a control system of theinvention for controlling a network of cogeneration plants is configuredreceive an average of over 5000 inputs per 10 minute interval. Incertain embodiments a control system of the invention for controlling anetwork of cogeneration plants is configured receive an average of over10,000 inputs per 10 minute interval.

Inputs from Cogeneration Plants The receiving system is configured toreceive inputs from the cogeneration plant or plants that it controls.These inputs may be from sensors, as described herein. In embodimentswhere the cogeneration plant is a modular cogeneration plant, thesensors are fully integrated into the modules and into the plantassembled from the modules. Further input for a particular cogenerationplant may include the time of day for the plant, the time of year, orthe day of the week.

Inputs from Distribution System Inputs from the distribution system forthe cogeneration plant include inputs regarding the distribution ofelectrical power and distribution of thermal product or products.Examples of inputs from the thermal distribution system include inputregarding an incoming (return) thermal product carrier, e.g. coolingfluid such as chilled water, flowrate, an outgoing (supply) thermalproduct carrier, e.g. cooling fluid such as chilled water, flowrate, anincoming (return) thermal product carrier, e.g. cooling fluid such aschilled water, temperature, an outgoing (supply) thermal productcarrier, e.g. cooling fluid such as chilled water, temperature, anincoming (return) thermal product carrier, e.g. cooling fluid such aschilled water, pressure, and an outgoing (supply) thermal productcarrier, e.g. cooling fluid such as chilled water, pressure, and a powerinput to the distribution system. Similar inputs may be receivedregarding the distribution of a mechanical work product.

Inputs from Host Facilities Inputs from host facilities include inputsregarding an electrical energy demand, a thermal product demand, athermal product carrier flow rate, an air temperature, a thermal productcarrier temperature, a fan rate, a humidity, a set point for an airtemperature, a set point for a thermal product carrier temperature, amechanical work product demand, a mechanical work product carrier flowrate, or any combination thereof. A thermal product may be chilling,supplied (carried) by a chilled water product such as chilled water orice, or a heating, supplied (carried) by heated water product, such ashot water or steam. The host facility or facilities may have severaldifferent areas where there are corresponding set points for variousconditions, e.g., temperature and/or humidity, so that the controlsystem may receive temperature and/or set point inputs for at least 2,3, 4, 5, 6, 7, 8, 9, 10, 12, 15, 20, 30, 40, 50, 60, 70, 80, 90, or 100areas of the host facility. Corresponding fan rates may also be input.See the following section on combined thermal distribution and energystorage for possible inputs into the controller from the host facilityor facilities.

Input from a host facility may also include input from an operator ofthe host facility, i.e., facility operator-generated inputs, regardingone or more aspects of the operation of the facility, for example, achange in a desired temperature in the facility, or a change inscheduling, and the like, as described herein.

Other conditions, such as CO2 concentration in one or more areas of thehost facility, may also serve as input to the control system.

The control system may also receive input from an interface for anoperator of a host facility. The interface may allow the operator toinput into the control system a desired future modulation in theconditions of the host facility, such as inputting a desire to be ableto run an unscheduled shift at the plant, or remove a scheduled shift,desired changes in set points, and the like. The control system may beconfigured to receive such input and to adjust operating conditions ofthe cogeneration plant accordingly. In addition, the control systemreceives inputs regarding operator overrides of the control systemoutputs, and, in some cases, answers to queries from the control systemas to the reason for the overrides, as described more fully elsewhereherein.

In addition, the input from the host facility may include some or all ofthe transport logistics for products of the host facility, or any othersuitable input regarding the operation of the host facility.

Inputs from the Environment The control system may also be configured toreceive inputs regarding one or more environmental conditions around thecogeneration plant and/or its host facility or facilities, including oneor more of temperature, humidity, wind speed, wind direction, time ofday, and air pressure. Other environmental inputs for areas outside thatof the cogeneration plant or its host facility or facilities may also beinput as appropriate, e.g., weather patterns or conditions for otherareas.

Inputs from External Sources The control system is also configured toreceive inputs from one or more external sources. These sources includeany suitable and available sources to allow the control system toconduct the processing to provide outputs. The sources include marketsources, databases, weather sources, etc. Market sources provide inputregarding market conditions for markets relevant to the operating of thecogeneration plant, including a price for a fuel for the cogenerationplant, a price for electrical energy exported from the cogenerationplant, a price for imported electrical energy to the cogeneration plant,a price for an incentive for the cogeneration plant, a price for ademand response action offered by the electric utility, a price for athermal product produced by the cogeneration plant, a price formechanical work product produced by the cogeneration plant, a price forwater, and/or a price for a variable maintenance price. The criteria onwhich an incentive or incentives is based may include environmentalcriteria, reliability criteria, technological criteria, size criteria,availability criteria, or a combination thereof.

Processing System The control system processes the inputs and determinesone or more set points for one or more actuators within the cogenerationplant or plants, where the actuators are as described herein. In certainembodiments where a cogeneration plant is made of modular transportableunits, at least some of the actuators are actuators within modulartransportable units that are part of a cogeneration plant or plants. Insome cases the control system determines set points for actuators withinone or more host facilities. The control system may determine otheroutput as well, such as output to a utility indicating that electricpower is available from the cogeneration plant for sale to the utility,or to a facility that is not a host facility indicating that thermalproduct and/or mechanical work product is available from thecogeneration plant, or the like.

In addition to inputs, the processing system also uses information fromone or more agreements with one or more host facilities for providingelectric power and/or thermal product and/or mechanical work product tothe one or more host facilities. In a simple case, the cogenerationplant (i.e., the owner or operator of the cogeneration plant) is underan agreement with a host facility to provide it with electric power anda thermal product, e.g., chilling to a chilled facility, and/ormechanical work product. However, any number of host facilities may bein any number of agreements with a given cogeneration plant and theprocessing takes into account all relevant agreements. The terms ofadditional agreements may also be used by the processing system, such asagreements with utilities to purchase excess electric power from thecogeneration plant, often using real time pricing (RTP), whose valuescan be part of the inputs to the control system, maintenance agreements,labor agreements, supply agreements, agreements with facilities topurchase excess thermal product, agreements with facilities to purchaseexcess mechanical work product, agreements regarding emissions controland/or incentives, agreements regarding emissions credits, and any othersuitable agreements that could affect how the cogeneration plant orplants is operated. For some or all of these agreements, there may beperiodic inputs to the processing system to update current conditions ofthe agreement, e.g., current pricing or current options available underthe agreement, e.g., RTP as mentioned.

The processing system may also use information from one or more sourcesregarding a particular cogeneration plant and/or its components, e.g.,performance curves. For example, the processing system may useinformation, e.g., performance curves, regarding the manufacturersspecifications for one or more components, such as for one or more primemovers, e.g., turbines, one or more heat transfer systems, such as HSRG,e.g., HRSGs, one or more thermal product carrier producers, such asrefrigeration units, e.g., steam-driven compression refrigeration units,one or more mechanical work product producers, and the like. Theprocessing system may use information for the plant and/or variouscomponents that was determined during the commissioning of the plant.The processing system may use information that is gathered during therunning of the plant, e.g., updated performance curves for the variouscomponents.

The processing may include determining the outputs that will lead todesired result, such as an optimal result for a cogeneration plant, suchas a maximum profit for the cogeneration plant over a desired timeperiod, or maximum energy efficiency for the cogeneration plant over adesired time period. In some cases part of the processing may bedirected to optimizing maintenance as well as optimizing operations,such as by using a diagnostics unit to compare predicted values withactual values for various set points and results determined by theprocessor, see, e.g., FIG. 4. In certain embodiments, the processingsystem may also allow for the integration with, monitoring, andoptionally, control, of existing or future energy efficiency and/orrenewable energy systems; for example, a solar installation, variablespeed equipment in the facility, or predictive models of energyconsuming equipment in the facility may be incorporated into theprocessing of the processor system. In the case of a control system thatcontrols more than one cogeneration plant, i.e., a network ofcogeneration plants, the processing may include determining the outputsthat will lead to an optimal result for the network of plants, such as amaximum profit for the network or a maximum energy efficiency for thenetwork, over a desired time period. It will be appreciated that in suchnetwork control systems the optimum result for the network as a wholemay not be optimum for any one particular cogeneration plant in thenetwork.

Forecasting The processor system may use one or more forecast steps indetermining its output, e.g., in determining a set point or set pointsfor one or more actuators. The forecast step may include forecasting afuture value or range of values for a particular quantity, and may alsoinclude a probability of occurrence for the value or range of values atthe forecast time (which may be a single time or range of times). Theforecast step or steps may include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, ormore than 10 forecast scenarios. The forecast step or steps may includea forecast and/or probability for a value or range of values of a fuelprice (e.g., a natural gas price), an electricity export price, anelectricity import price, an ambient environmental condition (e.g.,weather, such as a prediction of change of air temperature), anemissions limit, an incentive for the cogeneration plant, a price for athermal product, a price for a mechanical work product, a price forwater, an electrical demand from a host facility, and/or a thermalproduct demand from a host facility, and/or a mechanical work productdemand from a host facility.

Learning The processor system may also have learning capability. Theprocessor system may, for example, include a data storage unit forstoring a value corresponding to a result that occurs after a change inone or more set points. It can compare the result with a predictedand/or ideal result, and based on the comparison, improve the ability ofthe control system to reach a desired result, such as an optimum result,e.g. an optimum profit, for the cogeneration plant. Learningcapabilities may extend far beyond such simple comparisons, and anysuitable learning system may be incorporated in the processor systemsoftware.

Profiles and Peer Sites At any single cogeneration plant such learningwill result in profile for that cogeneration plant, which includes theset of algorithms, databases, and other parts of a processing system,that most closely approximates the predicted behavior of the plant,based on plant component specifications, past behavior of the plant,past behavior of one or more host sites, and/or past environmentalconditions and their changes, and the like. The profile for the plantchanges as the system continues to learn at the particular site, and/oras the system learns from other sites.

A profile for a cogeneration plant includes performance curves for themajor components of the plant, such as one or more primemover/generators, e.g., one or more turbine generators, one or more heattransfer systems such as HRSGs, e.g., HRSGs, one or more thermal productcarrier producers such as one or more refrigeration units, e.g.,steam-driven compression refrigeration units and/or absorptionrefrigeration units, and one or more cooling towers. An initial set ofperformance curves may be the off-the-shelf curves provided by each ofthe manufacturers of the components. Another set may be produced duringcommissioning of the cogeneration plant. Further modification of theperformance curves will continue as the cogeneration plant is operated,and the modifications incorporated into the processing of the controlsystem; this may continue as the plant is operated over time. In anetwork of cogeneration plants, one or more of the performance curves ofone or more plants may be used to enhance control of other plants; e.g.,if a first cogeneration plant has been in operation longer than otherplants at peer sites, the information on performance over time of thefirst plant can be incorporated into the information used to control theother plants. Even if the plants aren't under a common controller thismay be done; however, the use of a common controller allows virtuallyinstantaneous adjustment for some or all of the plants in the network asperformance curves and other performance information is received andprocessed from one or more plants.

Such learning from peer site allows a forecast of asset degradation, inthat one can see how components in one plant in a network age undercertain conditions, and use that info to refine algorithms for others.This can be used for larger components, eg. turbines, refrigerationunits, and the like, but also lower level components, like pipes orblades.

In addition, a particular plant may have one or more peer sites, thatis, sites where conditions are similar enough that what is learned atone site may be applicable to the other sites. A collection of peersites that is grouped together according to one or more criteria is apeer group. For example, cogeneration plants that are located in variousparts of an agricultural area, where the plants are connected tofacilities for keeping agricultural products chilled, could be one setof peer sites that is grouped in a peer group.

The criteria for including one or more sites in a peer group can bedetermined with various degrees of rigor, and the system can learn whatcriteria produce the best results for peer sites included in a groupaccording to those criteria. For example, a peer group can beestablished based on the host site being a chilled facility, but thecriteria may be further refined so that one peer group includes onlyhost facilities that are chilled agricultural product facilities (oreven one particular type of agricultural product facility) and anotherpeer group includes only host facilities that are meat storagefacilities (or even particular types of meat storage facilities, such asfish storage vs. beef storage). It will be appreciated that the criteriafor inclusion in a peer group may be made as broad or narrow as desired,and that the system can learn and change over time to include more orfewer plants in a particular peer group, based on results usingparticular peer groups. The system can also set up any number of“thought experiments” where it virtually groups plants into peer groupsbut does not yet change any of the operating conditions at one plantbased on the others, but instead predicts what would have happenedshould one or more criteria in one or members of the virtual group havebeen changed based on the behavior of one or more other members. If theresults of such thought experiments indicate that a particular groupingwould result in better performance at individual plants and/or in thesystem as a whole, the criteria for that grouping may be incorporatedinto actual groupings and actual changes of operating conditions at oneor more plants. The system is capable of a virtually infinite number ofsuch thought experiments, and may learn through modeling, empirically,or both, and in some cases may continually adjust peer groupings basedon ever-changing and ever-refined groupings and results.

In addition, a plant may belong to more than one peer group, where thedifferent peer groups are based on different criteria, and the controlsystem can determine whether what is learned in one of a plant's peergroups is applicable to that particular plant or not. For example, onepeer group may be based on size of turbine, or type of turbine, or sizeand type of turbine, and a plurality of plants with a particular sizeand/or type of turbine may belong to that particular peer group, whichlearns from its members, e.g., changes in performance curves over timein the plants that have been on-line the longest may be incorporatedinto control system processing systems for the other, younger plants topredict maintenance and repair behavior, and other characteristics, moreprecisely. A plant in one “turbine” peer group may also belong to otherpeer groups based on other criteria, e.g., plants located in hot areaswith high chilling demands for their host sites, and learn from otherplants for specific conditions for this peer group. A single plant maybelong to 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10 peer groups andlearn from one or more members of one or more of its peer groups, andadjust its control logic according to what is learned at the otherplants. In addition or instead of the thought experiments describedabove, the system can perform actual experiments to determine how tightor loose the criteria are for a particular peer group to generate usefullearning—for example, for a turbine peer group where members are plantswith turbines in a range of particular sizes and of a particular type,the system can experiment to see whether expanding or contracting therange of sizes achieves a better or worse result for the peer group as awhole, or whether, e.g., adding more criteria to narrow the peer groupis useful, e.g., the group might be narrowed to only include plants inareas with certain weather patterns. These are mere exemplary groupingsto illustrate the concept of multiple and/or shifting peer groups, andit will be appreciated that the system may be set up to learn over timewhat peer groups provide optimal feedback, and that such learning willtypically be continuous and shifting.

Thus, the profile for a particular cogeneration plant can changeaccording to what is learned locally at its host site, what is learnedat one or more peer sites, or a combination of both. In certainembodiments, some or all of the peer sites are sites within a network ofcogeneration plants, and software updates based on changes of profile atone peer site may be shared with some or all of the other peer sites aparticular peer group. This may be done automatically, e.g., automaticsoftware updates, or manually, or a combination of both.

In certain embodiments, the control system learns from operator actions.The cogeneration plant will supply electrical power and/or thermalproduct and/or mechanical work product to one or more host sites.Typically at one or all of the host sites, the operator of the host sitewill have the ability to override the action that the control system hasdetermined and cause the system to take another action or not take aparticular action. In many cases, operator overrides occur with acertain pattern, e.g., the operator requests more or less electric poweror more or less thermal product or more or less mechanical work productthan the control system has determined, or a different time interval orramp-up or ramp-down curve than the control system has determined, orthe like, in a way that becomes predictable with enough overrides. Forexample, at a chilled facility, an operator may override the controlsystem output that calls for actions to lead to a certain temperature insome or all of the facility, and the override temperature may be higheror lower than the control system temperature. The control system inthese embodiments can sense overrides, detect the pattern, and adjustits processing to take into account the pattern. This can occur at asingle plant, or multiple plants in a network, some or all of which maylearn from operator actions, e.g., overrides, at the others. Additionalinformation may also be used in the learning, for example, the controlsystem may query the operator regarding conditions that prompted anoverride or other action. As a cogeneration plant or set of plantslearns to predict the actual behavior of operators at one ore more oftheir host facilities, the control system may adjust to provide optimumperformance given the actual pattern of operator demands. Such learningwill typically be continuous and the results refined over time.

In certain embodiments, the control system may perform an experiment onone or more cogeneration plants. The experiments may be “thoughtexperiments” or real experiments.

The system can also set up any number of “thought experiments” where itvirtually groups plants into peer groups but does not yet change any ofthe operating conditions at one plant based on the others, but insteadpredicts what would have happened should one or more criteria in one ormembers of the virtual group have been changed based on the behavior ofone or more other members. If the results of such thought experimentsindicate that a particular grouping would result in better performanceat individual plants and/or in the system as a whole, the criteria forthat grouping may be incorporated into actual groupings and actualchanges of operating conditions at one or more plants. The system iscapable of a virtually infinite number of such thought experiments, andmay learn through modeling, empirically, or both, and in some cases maycontinually adjust peer groupings based on ever-changing andever-refined groupings and results.

In real experiments, for example in one or more cogeneration plants in anetwork, one or more outputs is changed to be different from the outputof the current processing system, e.g., a turbine may be operated at adifferent level than called for by the current processing system, andthe results evaluated to determine if the change in output produced abetter or worse result than would have been expected from the currentprocessing system output, for example, a higher or lower profit thanwould otherwise have occurred. It will be appreciated that, so long ascustomer agreements with the host facilities are met, such experimentsmay be conducted as often as desired by the operator of the cogenerationplant. The control system can then adjust the algorithms used by theprocessing system according to the results. In a network of cogenerationplants, a plant or a set of plants may be used for experiments todetermine if certain changes can further optimize operations, and theresults of at least some experiments will lead to less than optimalresults for the plant or set of plants, as described herein for peergroups. The learning from experiments will ultimately optimize theoperation of the network as a whole, as the results of successfulexperiments are incorporated into improvements in software which can bedistributed virtually instantaneously to all plants in the network, orto subsets of plants, for example, to peer sites for the plant or plantsat which the experiments were performed. Even the results of failedexperiments can be used to further optimize operations by, e.g.,changing probabilities used in forecasts, or by changing the weightingof one or more possible results from one or more scenarios beingcompared by the system, etc.

Other methods by which the control system may learn and/or improve itsperformance include, e.g., artificial intelligence, machine learning,and evolutionary algorithms.

The processing system is configured to determine the outputs that willcause a desired result, such as an optimal profit, or an optimal energyefficiency, for the cogeneration plant or plants, as described herein.Other desired results may include, e.g., lower carbon emissions, whichmay be useful to comply with regulations or to obtain revenues forcarbon credits, e.g., in a cap and trade system (e.g., Europe) or othermechanism by which a plant gets money for lowering emissions. The samemay be true for other emissions, such as pollutants. Although in certainembodiments the emissions credits may contribute to maximizing profits,in other embodiments the emissions credits have more weight and may insome cases be maximized or increased even at the expense of maximumprofit.

The processing system may periodically update its control logic based onany or all of the learning methods described herein. The processingsystem may update its control logic an average of at least monthly, orat least biweekly, or at least weekly, or at least daily, or more thanonce per day. The processing system may also send out periodic updatesto subsystems within individual cogeneration plants or sets ofcogeneration plants, e.g., members of a peer group, based on learning bythe processing system and/or based on other factors. This is the caseespecially when some plants have certain parts of the processing systemwithin the plant itself.

Outputs The outputs of the control system govern the action of one ormore actuators or actuator systems at the cogeneration plant or plantsunder the control of the control system. Other outputs may be directedto a host facility or facilities, the operator or owner of thecogeneration plant, or any other suitable destination. In certainembodiments where one or more of the cogeneration plants to whichoutputs are directed is a plant assembled from modular transportableunits, at least some of the actuators are part of one or more modulartransportable units that have been assembled into the cogenerationplant.

The actuators to which output is directed may be any suitable actuatorsuch as those described herein. These actuators may include on/offactuators as well as actuators that work over a continuum. Actuators mayinclude one or more of actuators to control a flow rate, e.g., via avalve, a pump, a fan, etc., actuators to control an electrical signal,actuators to control mechanical systems, and the like. Actuators of theinvention may include one or more of an actuator or actuator system forcontrolling a pre-cooler, an actuator or actuator system for controllinga turbine, an actuator or actuator system for controlling a heatrecovery steam generator, an actuator or actuator system for controllinga thermal product carrier producer, an actuator for controlling amechanical work product producer, an actuator or actuator system forcontrolling a cooling tower, an actuator or actuator system forcontrolling one or more distribution pumps, and, optionally, an actuatoror actuator system for controlling a thermal energy storage productproducer.

A control system of the invention may be configured to transmit anynumber of suitable outputs in a given time period. For example, acontrol system may be configured to transmit at least 6, at least 7, atleast 8, at least 9, at least 10, at least 12, at least 14, at least 16,at least 18, at least 20, at least 50, at least 100, at least 200, atleast 500, at least 1000, at least 2000, at least 5000, or at least10,000 outputs, to a corresponding number of actuators, in a given timeperiod, on average. The time period may be, e.g., a minute, 5 minute, 10minutes, 30 minutes, an hour, or a day. For example, in certainembodiments a control system of the invention is configured to transmitan average of at least 20 outputs per 10 minute interval. In certainembodiments a control system of the invention is configured to transmitan average of at least 100 outputs per 10 minute interval. In certainembodiments a control system of the invention is configured to transmitan average of at least 200 outputs per 10 minute interval.

Control systems that control a network of cogeneration plants may beconfigured to transmit even more outputs in a given time period. Forexample, a control system that controls a network of cogeneration plantsmay be configured to transmit at least 20, at least 50, at least 100, atleast 200, at least 500, at least 1000, at least 2000, at least 5000, atleast 10,000, or at least 20,000 outputs to a corresponding number ofactuators in a given time period, on average. The time period may be,e.g., a minute, 5 minutes, 10 minutes, 30 minutes, an hour, or a day.For example, in certain embodiments a control system of the inventionfor controlling a network of cogeneration plants is configured transmitan average of over 200 outputs per 10 minute interval. In certainembodiments a control system of the invention for controlling a networkof cogeneration plants is configured transmit an average of over 1000outputs per 10 minute interval. In certain embodiments a control systemof the invention for controlling a network of cogeneration plants isconfigured transmit an average of over 2000 outputs per 10 minuteinterval.

In embodiments where the control system controls a cogeneration plantthat is assembled from modular transportable units, the variousnecessary components for the control system that are required for thefunction of the control system, e.g. sensors for input to the controlsystem from the cogeneration plant, and actuators or actuator systemsfor receiving outputs from the control system, are fully integrated intothe modular transportable units from which the cogeneration plant isassembled, so that the fully assembled plant has the necessary sensors,actuators, and systems, connected in fully integrated workable assembly,to provide input to a controller and receive output from the controllerto achieve an optimum result for the cogeneration plant, or for thenetwork of cogeneration systems of which it is a part, e.g., an optimumprofit. The modular transportable units are designed so that, in theirfinal configuration in the fully assembled cogeneration plant, thecontrol system is ready to use for optimum result, without substantialmodification and preferably with no modification. The modulartransportable units are also configured to receive input from outsidesources, such as from the one or most host facilities, in a mannersuited to optimizing the performance of the cogeneration plant.

In some cases, one or more of the host facilities has the capacity toinstall the necessary sensors and/or actuators to seamlessly integratewith the cogeneration plant, for example, if the host facility orfacilities is built at the same time or after the cogeneration plant isbuilt. In many cases, the host facility or facilities will already existand the cogeneration plant will be required to retrofit or use existingsensors, actuators, and/or control systems. The appropriate modules ofthe cogeneration facility can be provided with suitable adaptors foradapting to the input, from the host facility or facilities, either asan integral part of the module or as one or more accessories that ischosen based on the particular host facility or facilities to which aunit is sent. In addition, a controller input adapter unit may be usedto adapt inputs from the host facility to be suitable to be sent to thecogeneration plant controller, as well as to adapt outputs from thecontroller to be suitable for transmission to the host facility orfacilities, given the particular configuration of the host facility orfacilities. Packages of sensors, actuators, and or control systems maybe also used by the supplier of the cogeneration plant as part of thepackage sent to the host site. Such packages may be made up of standardsubunits kept in supply or readily accessible to the supplier, based onknown or predictable configurations of host facility equipment.

IV. Networks of Cogeneration Systems

In certain embodiments the invention provides networks of cogenerationsystems, where each system includes a cogeneration plant that isoperably connected to a host facility or facilities that receive athermal product and/or electrical power and/or mechanical work productfrom the plant, and a common controller for the cogeneration systemsthat receives inputs from more than one sensor at or near each of thecogeneration systems, processes the inputs to determine a plurality ofoutputs, and transmits the outputs to a plurality of actuators in thesystems, whereby the operation of the network is optimized. Optimizationof the network can include optimizing the profit for the network and/oroptimizing the energy efficiency for the network, or part of thenetwork.

In certain embodiments, at least one of the cogeneration plants in atleast one of the cogeneration systems includes more than one operablyconnected modular transportable units in the assembled plant.

In certain embodiments, the network includes at least 2, 3, 4, 5, 6, 7,8, 9, 10, or more than 10 cogeneration systems, such as at least 20cogeneration systems, or at least 50 cogeneration systems, or at least100 cogeneration systems. In certain embodiments, the network includes2-5000 systems. In certain embodiments, the network includes 5-5000systems. In certain embodiments, the network includes 10-5000 systems.In certain embodiments, the network includes 100-5000 systems. Incertain embodiments, the network includes 100-5000 systems. In certainembodiments, the network includes at least 2, 3, 4, 5, 6, 7, 8, 9, 10,or more than 10 cogeneration systems where a cogeneration plant in eachsystem includes a modular transportable unit, such as a plurality ofmodular transportable units that are operably connected into the finalplant. It will be appreciated that the network may expand or contract,so that the exact number of plants in the network does not necessarilyremain constant. The common controller may be configured to easily andautomatically accommodate expansion or contraction in the number andtype of cogeneration systems in the network, and to accommodateexpansion or contraction in inputs and outputs.

The embodiments in which a cogeneration plant includes modulartransportable units include any of the units and connections describedherein, including any of the sensors and actuators that are part of themobile transportable units. Thus, in certain embodiments, the commoncontroller for the cogeneration network receives inputs from at least 1,2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 50, 100, 150, 200, 250, 500,1000, 5000, 10,000 or more than 10,000 sensors. In certain embodiments,the common controller is configured to receive and process inputs fromat least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 50, 100, 150,200, 250, 500, 1000, 5000, 10,000 or more than 10,000 sensors. Incertain embodiments the common controller is further configured toreceive inputs from at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25,30, 50, 100, 150, 200, 250, 500, 1000, 5000, 10,000 or more than 10,000sources that are not sensors. In certain embodiments the commoncontroller is configured to transmit outputs to at least at least 1, 2,3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 40, 50, 60, 70, 80 90, 100,120, 140, 160, 180, 200, 250, 300, 350, 400, 450, 500, 600, 700, 800,900, 1000, 5000, 10,000 or more than 10,000 actuators. In certainembodiments, some or all of the sensors and actuators are configured tointegrate into their particular cogeneration system, and into thecontrol system for the network, with little or no modification.

Other attributes of the common control system for a network ofcogeneration systems are as described previously for control systems ingeneral, and any or all of these attributes may be present in a commoncontrol system for a given network of cogeneration systems.

In certain embodiments, one or more third party cogeneration plants,i.e., cogeneration plants owned by an entity other than the entity thatowns the cogeneration plants in the network, or renewable generationplants, or other distributed energy plants may connect to the network.The third-party plant may be in one way communication with the networkor two way communication with the network. One way communication may beeither providing new data to the network without receiving networkinformation, or receiving information from the network, e.g., receivingbeneficial information from the network such as receiving suchinformation in return for consideration, for example payment, withoutproviding data to the network.

In one embodiment the invention provides a network of cogenerationsystems where the network includes a first cogeneration system and asecond cogeneration system, where the first cogeneration system includesa first cogeneration plant that includes a plurality of modulartransportable units that are operably connected and a first hostfacility that receives electric power and/or a thermal product from thefirst cogeneration plant under a first agreement, and the secondcogeneration system includes a second cogeneration plant that includes aplurality of modular transportable units that are operably connected anda second host facility that receives electric power and/or a thermalproduct from the second cogeneration plant under a second agreement,optionally a third host facility that receives mechanical work productfrom a third cogeneration system under a third agreement, and a commoncontroller that contains a receiving system for receiving inputs from aplurality of sensors in a plurality of the modular transportable unitsin the first cogeneration plant and the second cogeneration plant, fromthe host facilities, and from external sources, a processing unit forprocessing the inputs to achieve a desired operating result, such as anoptimal operating result for the network while meeting an obligation inthe first agreement and an obligation in the second agreement, and atransmitting unit for transmitting a plurality of outputs to a pluralityof actuators in a plurality of the modular transportable units in thefirst cogeneration plant and the second cogeneration plant so as toachieve the desired operating result, e.g., an optimal operating resultfor the network. The optimal operating result may be a result in adesired period of time, such as an average result over a week, a month,a quarter, more than one quarter, or a year. In certain embodiment, theoptimal operating result for the network is an optimal profit for thenetwork, e.g., the highest profit for the network. In certainembodiments, the optimal operating result is an optimal energyefficiency for the network or part of the network, e.g., a maximalenergy efficiency.

The optimal result for the network may be achieved while one or more ofthe cogeneration systems does not achieve an optimal result. This canhappen in a variety of ways. As described elsewhere herein, the controlsystem may perform experiments at one or more of the cogenerationsystems in the network in order to determine if a better or worse resultis achieved by changing one or more operating conditions at thesystem(s); if the result is a worse result, the particular system maynot achieve an optimum result but the rest of the network may beoptimized to avoid the worse result and thus function overall at a moreoptimal level. In another example, it may be more profitable for thenetwork as a whole to have one or more of the cogeneration plantssupplied with a fuel, e.g., natural gas, under a single supply and/orhedging agreement that optimizes fuel costs for the network overall,even though the supply and/or hedging agreement may require a particularcogeneration plant to take the fuel at a price that is higher than aprice that is locally available to the plant. In yet another example,multiple cogeneration systems may supply, e.g., a thermal product to thesame end user, e.g., a company that operates several different coldstorage facilities. The overall agreement with the end user, coveringsome or all of its commonly-owned facilities, may not provide foroptimal operation of one or more plants within the group of commonlyowned facilities, but the group as a whole may be operated to produce anoptimal result for the group, e.g., an optimal profit.

In embodiments where the network include a group of cogeneration systemsthat are operated by a single end-user, part of the inputs and outputsof the control system may include inputs and outputs related torelationships between the facilities, to optimize the use of electricalpower, thermal product, mechanical work product, or any combinationthereof, so that the operator of the network achieves a better resultand the end-user is not harmed and, preferably, also has an improvedresult. For example the network control system may link with thelogistics function of the end-user to divert shipments between hostfacilities in such a way that the operations of the end-user are notharmed and, preferably, are improved, while at the same time theoperations of the cogeneration network as a whole is improved.

In certain embodiments, the invention provides systems and methods forproviding mechanical work to existing or new host facility systems.

VI. Combined Thermal Distribution and Storage Systems

In certain embodiments the invention provides systems and methods forstoring thermal energy and distributing a thermal product carrier thatincludes (i) a thermal product carrier producer that produces a thermalproduct carrier; (ii) a distribution system that distributes the thermalproduct carrier to a facility that uses the thermal product carrieraccording to a need for a thermal product; and (iii) a controlleroperably connected to the distribution system and to the thermal productcarrier producer, where the controller is configured to modulate theoperation of a first part of the distribution system and a second partof the distribution system based on inputs from the facility and fromthe distribution system, such that that the energy required to providethe thermal product carrier to the facility that uses it according tothe need for it is optimized.

In certain embodiments the invention provides systems and methods forstoring chilling potential and distributing chilling potential thatinclude (i) generating a chilled water product with a refrigeration unitin a cogeneration plant; (ii) transporting the chilled water product toa facility that requires a time-varying amount of chilling potential;(iii) distributing the chilled water product to one or more areas in thefacility; (iv) running the chilled water product through a coil in theone or more areas of the facility; and (v) moving air in the one or moreareas across the coil with a variable-speed fan; (vii) controlling thespeed of the fan according to the chilling needs of the area, such thatduring low chilling need periods the fan runs slowly or is turned off,and during high chilling need periods the fan runs more quickly, andsuch that the chilled water product in the coil varies in temperature,thus storing chilling potential during low demand times and releasing itduring high demand times.

In some of these embodiments, the thermal product carrier, e.g., thechilled liquid, undergoes a phase change in part of the system, e.g.,from liquid to solid, such as from liquid water to ice. In certainembodiments, the ice may comprise food-grade ice. A part of the systemmay be constructed so as to allow the phase change, e.g. constructed soas to allow the expansion from liquid water to ice, and to convert thethermal product carrier from one state to another and back again. Insome embodiment the thermal product carrier, e.g. water, remains in asingle phase, e.g., liquid water.

In certain embodiments the invention includes systems and methods forpeak shifting a thermal product carrier producer load, such as arefrigeration unit load, by storing and releasing thermal energy fromthe thermal product carrier producer, e.g., refrigeration unit, in adistribution system for the thermal product carrier. In this way thethermal product carrier producer, e.g., refrigeration unit, can operatecloser to its optimal operating load for more of the time than wouldotherwise occur. For example, the system and methods may allow arefrigeration unit to operate within a certain percentage of its mostefficient operating load, e.g. within 5%, or 10%, or 20% of its mostefficient operating load, for a certain average amount of time, e.g., atleast 70%, at least 80%, or at least 90% of the time, on average, over agiven time period, e.g. one month, two months, three months, or thelike.

For example, in certain embodiments, the invention provides systems andmethods for storing chilling potential and distributing chillingpotential that include (i) a refrigeration unit that produces a chilledwater product, wherein the refrigeration unit operates continuously atbetween 60-100% load at least 90% of the time; (ii) a refrigeration unitexit conduit that transports the chilled water product to a facility inneed of chilled water product, wherein the conduit is operably connectedto the refrigeration unit and to the facility; (iii) a distributionsystem within the facility, operably connected to the refrigeration unitexit conduit, that distributes the chilled water product to one or moreareas in the facility in need of chilling; (iv) a heat transfer systemoperably connected to the distribution system, comprising aheat-conductive chilled water product conduit and a fan to move airacross the heat-conductive chilled water conduit, for transferring heatfrom the area in need of chilling to the chilled water product, toproduce a desired degree of chilling in the area, wherein the fan is avariable-speed fan; and (v) a collection system operably connected tothe heat transfer system for collecting chilled water product exitingthe heat transfer system; (vi) a refrigeration unit return conduitoperably connected to the collection system and to the refrigerationunit, that transports chilled water product from the facility to therefrigeration unit; and (vii) a control system operably connected to thefacility, the refrigeration unit, and the fans, where the control systemis configured to (a) receive inputs from sensors that detect temperaturein the facility, temperature of the chilled water product at variouspoints in the system, load of the refrigeration unit, flow rates of thechilled water product at various points in the system, and fan speedsfor the fans in the facility, and inputs from indicators of desiredtemperature in one or more areas of the facility; (b) calculate a fanrate, a flow rate for chilled water product, a load level for therefrigeration unit, a vent level for a thermal vent, or any combinationthereof; and (c) calculate a set point for a fan, a chilled waterproduct valve, a thermal vent valve, a refrigeration unit loadcontroller, or any combination thereof, based on the calculation of (b);and (d) output a signal or signals to adjust a fan speed, a chilledwater product valve position, a load level for a refrigeration unit loadcontroller, or any combination thereof.

The systems and methods taking advantage of the heat capacity of thethermal product carrier, its volume and, in some cases where part of thethermal product carrier undergoes a phase change, its heat of fusion orheat of vaporization.

The system and methods will be described in terms of a chilling systemfor a refrigerated facility but this is merely exemplary.

A cogeneration plant may provide chilling, carried by chilled water, toa refrigerated facility, where the chilled water is produced by one ormore refrigeration units, output to the facility through one or moreoutlets, distributed to the facility through a distribution system thatdistributes the water to various parts of the facility, e.g. variousrooms or areas, collected after it has moved through the facility intoon or more input conduits and returned to the refrigeration unit orrefrigeration units as one or more inputs. Individual areas receive thechilled water from the distribution system in one or more arrangementssuitable to increase the heat transfer capacity from the air to thechilled water, e.g., as coiled pipes. One or more variable-speed fans isused to pass air across the coiled pipe to transfer heat from the air tothe water inside the pipe, thus cooling the area. Individual areas orgroups of areas are controlled by thermostats, which receive input onthe air temperature in the area, and send output to the fans dependingon the set point for the area. As long as the area remains at thatdesired temperature, the transfer of heat from the air to the chilledwater may be accomplished by any combination of water temperature, waterflow rate, and air flow rate.

In the systems and methods of this aspect of the invention, therefrigeration unit or refrigeration units that produce the chilled waterare run at or near their optimal capacity for as much of the time aspossible. During times when the refrigerated facility needs little or nocooling, e.g., at night or during cooler days or seasons, the variablespeed fans are turned down or off by the control system, so that waterin the distribution system is allowed to decrease in temperature as therefrigeration unit continues to cool it and little or no heat istransferred to it in the distribution system. The system may beconfigured so that at some minimum temperature, below which the chilledwater will undergo a phase change to ice, the refrigeration unit rate orrefrigeration unit rates is reduced, but up to that point therefrigeration unit or refrigeration units are allowed to operate at ornear their optimal efficiency rates. The minimum temperature may bereduced by the addition of, e.g., glycol to the chilled water. This mayoccur in some cases on an ongoing basis, with glycol or water additionand bleeding occurring to keep the mixture at the proper concentrationfor the given conditions. The water acts as a buffer system and allowsthe refrigeration unit or refrigeration units to continue to run at ahigher rate than they would otherwise run, e.g., if the chilling of thefacility were controlled during times of low chilling demand bydecreasing the rate of operation of the refrigeration units. Instead,variable speed fans are controlled to reduce heat transfer. Thetemperature to which the water is allowed to go is limited by the volumeof water, the refrigeration unit rate, and the amount of additive, e.g.,glycol, in the water. These factors combine to give a certain amount ofbuffering for “chilling potential,” thus allowing the refrigeration unitor refrigeration units to run at a higher rate during low-demandperiods, and allow chilling potential to be stored in water in thedistribution system, and a lower rate during high-demand periods, whenstored chilling potential is released from the water in the distributionsystem; thus the system and methods are peak-shifting methods forthermal product carrier producers, e.g., refrigeration units.

In some configurations a bypass unit may be included in the distributionsystem. The bypass unit may serve as a source of additional volume forthe chilled water when the temperature of the water becomes low enoughthat, even with all fans off, the temperature of the air in one or moreareas of the refrigerated facility may dip below the set point for thatarea or areas; the bypass unit serves as a volume that is not in thermaltransfer contact with these areas where some or all of the chilled wateroutput from the refrigeration unit may be directed until chillingdemands of the area or area increase. In some cases the bypass unit mayalso include one or more areas where the chilled liquid may be allowedto become cold enough to undergo a phase change, e.g., water freezing toice, and ice melting to water, to add additional heat storage capacityto the unit.

In some embodiments, the system and methods may utilize deliberate andcontrolled phase change in order to maximize thermal energy storagecapacity. This can happen, e.g., in a bypass unit as described. It mayalso occur as, e.g., ice formation on coils in the facility, for examplecombined with a method of harvesting or melting the ice to recoup thethermal product.

Systems and methods may also include mechanisms for controlling forhumidity and dew point.

In certain embodiments, a cogeneration system of the invention includesa subcontroller for utilizing a thermal product carrier distributionsystem and temperature maintenance system in the host facility to bothdistribute a thermal product carrier and to store thermal energy. Thesubcontroller may receive inputs for one, 2, 3, 4, 5, 6, 7, 9, 10 ormore than 10, or more than 20, or more than 50, or more than 100, airtemperatures within the host facility, inputs for set points for one, 2,3, 4, 5, 6, 7, 9, 10 or more than 10, or more than 20, or more than 30,or more than 50, or more than 100 air temperatures within the hostfacility, and inputs for one, 2, 3, 4, 5, 6, 7, 9, 10 or more than 10,or more than 20, or more than 30, or more than 50, or more than 100 fanrates for variable speed fans within the host facility. Thesubcontroller may process the inputs to determine whether or not one ormore of the set points should be altered, and, if so, by how much, inorder to minimize perturbations in the rate of a refrigeration unit orrefrigeration units in the cogeneration system, for example, to keep therefrigeration unit or refrigeration units within a certain percentage ofits optimal efficiency operating rate for as much of the time aspossible, on average. In certain embodiments, the subcontrollerprocesses the inputs based on keeping the refrigeration unit orrefrigeration units within a range that is 1, 2, 3, 4, 5, 6, 7, 8, 9,10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, or 25% of the optimumefficiency percentage and the lower limit of the range is within 1, 2,3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, or25% of the optimum efficiency percentage, generally for as much time aspossible. These set points may include one or more set points for thefans in the facility, e.g., set points for 1, 2, 3, 4, 5, 6, 7, 8, 9,10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or more than 20, or morethan 30, or more than 50, or more than 100 fan rates for variable speedfans within the host facility, based at least in part on the range ofpercentages. The processing may be based, at least in part, on predictedalterations in one or more external temperatures at the host facility orfacilities. The predicted alterations may be based on one or more of thetime of day, the day of the year, a weather forecast, or a previousalteration in the external temperature, or any combination thereof.Inputs used to make the prediction may come from any suitable source,such as time keepers, databases, external weather prediction services,internal weather prediction services, and the like. The inputs to theprocessor, and its processing, may further include input regarding oneor more inlet temperatures and/or inlet flow rates for one or morerefrigeration units, one or more outlet temperatures and/or flow ratesfor one or more refrigeration units, one or more operating loads for oneor more refrigeration units, and any other suitable inputs.

In certain embodiments, the control system for a cogeneration plantincludes: (a) in its receiving system receivers for input from sensorsthat sense temperature in one or more areas of a facility to which thecogeneration plant distributes chilled water, and sensors that senseinlet and outlet temperatures and/or flow rates at the inlet and outletfor one or more refrigeration units; (b) a processing unit forprocessing the input from (a) to produce output to adjust actuators sothat the thermal load of the refrigeration unit or refrigeration unitsis peak-shifted to a higher rate for a low chilling period and a lowerrate for a high chilling period than would otherwise occur without theprocessing; and (c) in its transmitting system, transmitting units fortransmitting the output from (b) to one or more actuators or actuatingsystems that control one or more of refrigeration unit output rate, andthe rate of one or more variable-speed fans within the host facilitythat move air across one or more parts of the distribution system forthe chilled water.

Such systems and method of storing thermal energy in a thermal productcarrier distribution system may be incorporated into suitable systemsand methods as described herein; e.g., the control system for any of thesystems or methods described herein may include receiver for receivinginputs from the appropriate sensors in the appropriate facility,processing that includes appropriate logic for producing output, wherethe output goes to the appropriate actuators or actuator systems, e.g.,actuators or actuator systems that control the speed of one or morevariable speed fans, refrigeration unit output, and the like.

VII. Methods and Systems

In certain embodiments the invention provides a cogeneration systemcomprising: (i) a cogeneration plant operably connected to a hostfacility that receives a thermal or mechanical work product and,optionally, electrical power from the cogeneration plant under anagreement with the cogeneration plant, where the cogeneration plantcomprises a plurality of operably connected modular transportable units;and (ii) a control system operably connected to the cogeneration plantcomprising (a) a receiver system for receiving inputs from a pluralityof sources of input wherein the sources of input comprise input fromsensors in one or more of the modular units, inputs from the hostfacility, and inputs from indicators of market conditions, (b) aprocessor system operably connected to the receiver system forprocessing the inputs and determining outputs for modulating theactivities of a plurality of actuators or actuator systems in one ormore of the modular units achieve a desired result in the operation ofthe cogeneration plant based on the inputs and on the agreement; and (c)a transmitter system operably connected to the processor system fortransmitting the outputs to the actuators or actuator systems. Theoutput may include outputs based on one or more set points determined bythe processor system. The desired result may be an optimum profit forthe cogeneration plant. In certain embodiments the modular transportableunits exist in a first form that is a transportable form and second formthat is an assembled form, and the sensors and actuators are configuredso that when the transportable forms are assembled into the assembledform, the sensors or actuators are ready to transmit inputs to andreceive outputs from the control system without substantialmodification, or in some cases with no modification, from thetransportable form to the assembled form. In some cases, no modificationis required.

In certain embodiments of the system, a thermal product is moved fromthe cogeneration plant to the facility by a heat transfer fluid (thermalproduct carrier), which in certain embodiments may comprise water orsteam. In certain embodiments the heat transfer fluid (thermal productcarrier) comprises a chilled water product, such as chilled water orice, which may further comprises an additive, such as glycol.

In certain embodiments of the system, mechanical work is moved from thecogeneration plant to the facility by a compressed gas, such as arefrigerant, e.g., ammonia, or such as compressed air.

In certain embodiments of the system, the cogeneration plant comprisesat least 4 modular transportable units.

The host facility may receive electrical power from the cogenerationplant under the agreement.

The cogeneration plant may comprise an electrical generating systemoperably connected to a heat transfer unit, such as a heat recoverysteam generator (HRSG), such as where the electrical generating systemis contained in at least a first modular transportable unit and the heattransfer unit, such as a HRSG, is contained in at least a second modulartransportable unit. The cogeneration plant may further comprise athermal product carrier producer operably connected to the heat transferunit, e.g., HRSG, in some cases the thermal product carrier producer iscontained in at least a third modular transportable unit. The system mayfurther comprise a cooling tower or towers, air intake unit, and anexhaust stack, wherein the cooling tower or towers, air intake unit, andstack are operably connected with the electrical generating system, theHRSG, and the thermal product carrier producer, if present. In somecases, at least one of the cooling tower, air intake unit, or exhaustunit is contained in at least a fourth modular transportable unit. Thethermal product carrier producer comprises a refrigeration unit, such asa steam-driven compression type refrigeration unit. The electricalgenerator may comprise a gas turbine generator, such as a naturalgas-driven turbine. The system may also comprise a mechanical workproduct producers operably connected to the HRSG; in some cases themechanical work product producer is contained in an additional modulartransportable unit. The mechanical work product producer may compriseone or more steam turbine driven gas compressors such as screwcompressors or centrifugal compressors that produce a compressed gas.The compressed gas may be, e.g., a refrigerant such as ammonia andoptionally ties in to an existing or new external refrigeration systemat the host facility; for example, the cogeneration plant receives lowpressure refrigerant gas from the host via a low pressure tie-in andreturns high pressure refrigerant gas via a high pressure tie-in. Thelow pressure gas tie-in may be upstream of an existing electric motordriven compressor system and the high pressure gas tie-in may bedownstream of the existing electric motor driven compressor system, andthe resulting piping configuration may effectively bypass an existingcompressor system. In such embodiments, the existing electric motordriven compressors may remain in place as peaking units and/or standbypurposes.

In some embodiments of the system, one or more of the modulartransportable units may comprise a system for controlling emission of atleast 1, 2, 3, 4, 5, or all of NOx, NH3, SOx, CO, CO2, or particulates.

In certain embodiments, the sensors in one or more of the modular unitscomprise a sensors for 2, 3, 4, 5, 6, 7, 8, or more than 8 of sensing aHRSG exhaust temperature, a steam flow rate, a generator output, anexhaust temperature, a thermal product carrier outlet temperature, athermal product carrier inlet temperature, a thermal product carrieroutlet flow rate, a thermal product carrier inlet flow rate, amechanical work product carrier outlet flow rate, a mechanical workproduct carrier inlet flow rate, and/or at least one of a NOx, NH3, SOx,CO, CO2, particulate, or O2 emission.

In certain embodiments, the actuator or actuator systems control one ormore of (i) a temperature within the cogeneration plant, the firstfacility, or the second facility, (ii) a pressure within thecogeneration plant, the first facility, or the second facility (iii) aflow of a raw material (iv) an exhaust flow (v) a waste flow (vi) athermal product carrier flow (vii) an electrical power flow (viii) autility input, (ix) a supply input, x) a state of operation of a firstthermal product carrier producer, for example a refrigeration unit, (xi)a state of operation of a second thermal product carrier producer, forexample a second refrigeration unit, (xiii) a state of operation of aturbine, (xii) a state of operation of a turbine precooler, (xiv) astate of operation of a duct burner (xv) a state of operation of amechanical work product producer, or (xvi) any combination thereof.

In certain embodiments the actuators or actuator systems comprise 1, 2,3, 4, 5, 6, or 7 of an actuator or actuator system for controlling apre-cooler, an actuator or actuator system for controlling a turbine, anactuator or actuator system for controlling a heat recovery steamgenerator, an actuator or actuator system for controlling a carrierproducer, an actuator or actuator system for controlling a coolingtower, an actuator or actuator system for controlling one or moredistribution pumps, and, optionally, an actuator or actuator system forcontrolling a thermal energy storage product producer.

In some systems, the receiver is configured to receive inputs indicatingone or more environmental conditions at or near the cogeneration plant,such as environmental conditions that comprise at least 1, 2, 3, 4, 5,or 6 conditions from the set of conditions comprising temperature,humidity, wind speed, wind direction, time of day, and air pressure.

If the controller/receiver is configured to receive inputs regardingmarket conditions, in some cases the market conditions may comprise 1,2, 3, 4, 5 or all of a price for a fuel for the cogeneration plant, aprice for electrical energy exported from the cogeneration plant, aprice for imported electrical energy to the cogeneration plant, a pricefor an incentive for the cogeneration plant, a price for a demandresponse action, a price for a thermal product produced by thecogeneration plant, a price for a mechanical work product produced bythe cogeneration plant, a price for water, and/or a price for a variablemaintenance price.

In some cases the inputs from the host facility may comprise anelectrical energy demand, a thermal product demand, a thermal productcarrier flow rate, a mechanical work product demand, a mechanical workproduct carrier flow rate, an air temperature, a thermal product carriertemperature, a fan rate, a humidity, a set point for an air temperature,a set point for a thermal product carrier temperature, or anycombination thereof.

In certain embodiments, the control system is configured to receiveinputs from an operator of the host facility as described herein, suchas inputs from an interface for the operator to input desiredalterations in scheduling, etc.

In certain embodiments, the control system is configured to forecastand/or learn in any manner as described herein. For example, in certainembodiments, the control system is configured to make a forecast of oneor more future conditions of one or more inputs, expenses, revenues, orany combination thereof, for one or more future timepoints, andadjusting the determination of the output based on the prediction. Incertain embodiments, the determining of step (ii) is modulated or notmodulated based on a result of a past determination for an output, or aplurality of results of a plurality of determinations for a plurality ofoutputs. In some cases, the determining of step (ii) is modulated or notmodulated based on an input or plurality of inputs from an operator ofthe host facility, such as an override or a plurality of overrides of anoutput or plurality of outputs from the control system. Such forecastand learning functionalities are described in more detail elsewhereherein.

In certain embodiments the control system includes a subcontrol systemfor utilizing a thermal product carrier distribution system andtemperature maintenance system to both distribute a thermal productcarrier and to store thermal energy, as described herein. For example,in certain embodiments the subcontroller receives inputs for one, 2, 3,4, 5, 6, 7, 9, 10 or more than 10 air temperatures within the hostfacility, inputs for set points for one, 2, 3, 4, 5, 6, 7, 9, 10 or morethan 10 air temperatures within the host facility, and inputs for one,2, 3, 4, 5, 6, 7, 9, 10 or more than 10 fan rates within the hostfacility. The subcontroller controls fan rates and/or thermal productcarrier producer loads to keep the thermal product carrier produceroperating at or near a certain percentage of its optimal operating load.The subcontroller is described further elsewhere herein.

In certain embodiments, part or all of the control system is at alocation remote from the cogeneration plant and host facility, e.g.,part or all of the control system is Web-based.

In certain embodiments, the system is configured to operate over a threemonth, four month, five month, six month, 8 month, 10 month, or 12 monthperiod at an average efficiency of at least 80, 81, 82, 83, 84, 85, 87,88, 89, 90, 91, 92, 93, 94, or 95% when the host facility electricalpower demand and/or the host facility thermal product demand and/ormechanical work product demand vary by at least an average of 5, 6, 7,8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 25, 27, 30, 32,35, 37, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100% dailyduring the period. It will be understood that the percent variation iscalculated as the percent of the highest demand that is represented bythe lowest demand.

In certain embodiments the system is part of a cogeneration networkcomprising a plurality of cogeneration systems as described above. Inthis case, the desired result of the operation of a cogeneration plantwithin the network is designed to help achieve a desired result for theoperation and/or maintenance of the network, such as to help optimizethe operation and/or maintenance of the network, e.g. to optimize aprofit and/or energy efficiency for the network.

In certain embodiments the invention provides a method for achieving adesired result during a time period for a modular cogeneration plantcomprising (i) receiving inputs from (a) a cogeneration plant, whereinthe cogeneration plant comprises a plurality of modular transportableunits; (b) a first facility to which the cogeneration plant is obligatedto provide electrical power under a first agreement and a secondfacility to which the cogeneration plant is obligated to provide athermal product under a second agreement, (c) indicators of expenses orpotential expenses for the cogeneration plant, and (d) indicators ofrevenues or potential revenues for the cogeneration plant; (ii)determining an output to modulate the activity of an actuator in thecogeneration plant, the first facility, the second facility, or anycombination thereof, based on the inputs and on the first agreement andthe second agreement, wherein the output is determined to achieve adesired result in the time period for the operation of the cogenerationplant; and (iii) transmitting the output to the actuator or actuatorsystem to modulate the activity of the actuator or actuator to approachthe desired result; whereby the desired result for the cogenerationplant in the time period is achieved. The desired result is, in certainembodiments, an optimal profit for the cogeneration plant in the timeperiod. The time period is, in certain embodiments,

In certain embodiments of the method, a plurality of the inputs from thecogeneration plant are from sensors in the modular transportable unitsof the cogeneration plant, wherein the modular transportable units existin a transportable form and in an assembled form, and wherein thesensors are configured to be fully operational in the assembled formwith no substantial modification from the transportable form, asdescribed elsewhere herein, e.g., the sensors are configured to be fullyoperational in the assembled form with no modification from thetransportable form. The sensors may be any suitable sensors as describedherein.

In certain embodiments of the method, where the output is an output toan actuator or actuator system in a modular transportable unit of thecogeneration plant, and where the modular transportable units exist in atransportable form and in an assembled form, the actuator or actuatorsystem is configured to be fully operational in the assembled form withno substantial modification from the transportable form, as describedelsewhere herein, e.g., to be fully operational with no modification.The actuators may be any suitable actuators or actuator systems asdescribed herein.

In certain embodiments of the method, the cogeneration plant is part ofa network of cogeneration systems, as described herein. In these methodsthe desired result may be a desired result for the cogeneration networkand not necessarily the cogeneration plant itself, such as an optimumprofit for the cogeneration network.

In certain embodiments, the control system is configured to forecast asdescribed herein, and/or to learn, as described herein, such as to learnfrom operator overrides of outputs of the control system, or any othersuitable form of learning as described herein.

In certain embodiments part or all of the control system is remote fromthe cogeneration plant.

In certain embodiments the invention provides a cogeneration systemcomprising a cogeneration plant operably connected to a host facility towhich the cogeneration plant supplies a thermal or mechanical workproduct and, optionally, electrical power, and control system operablyconnected to the cogeneration plant and the facility, wherein thecontrol system comprises: (i) a receiver system for receiving inputsfrom a plurality of sources of input wherein the sources of inputcomprise input from sensors in one or more of the modular units, inputsfrom the host facility, and inputs from indicators of market conditions,(ii) a processor system operably connected to the receiver system forprocessing the inputs and determining outputs for modulating theactivities of a plurality of actuators or actuator systems in thecogeneration plant achieve a desired result in the operation of thecogeneration plant based on the inputs and on the agreement, wherein theprocessor system is configured to learn from an outcome of one or moreprevious outputs and adjust the determining of future outputs based onthe learning, or on an override of an output or a plurality of overridesof outputs by an operator of the host facility, or a combinationthereof; and (iii) a transmitter system operably connected to theprocessor system for transmitting the outputs to the actuators oractuator systems.

In certain embodiments of these systems, the system comprises aplurality of cogeneration plants operably connected to a plurality ofhost facilities, where the control system is a common control system forthe plurality of cogeneration plants, and further where the learningcomprises learning from an outcome of an output at a first cogenerationplant in the plurality of cogeneration plants and applying the learningto the determining step for an output for a second cogeneration plant inthe plurality of cogeneration plants, where the first and the secondcogeneration plants are different.

In certain embodiments the sensors and/or actuators or actuator systemare part of modular transportable units, as described elsewhere herein,such as sensor and/or actuators that require no substantial modificationto be fully operable when the units are converted from transportable toassembled forms.

In certain embodiments the invention provides a cogeneration systemcomprising a cogeneration plant that is operably connected to a hostfacility to which the cogeneration plant provides a thermal ormechanical work product and electrical power at a host site under anagreement, wherein the cogeneration plant comprises (i) a set ofoperably connected modular transportable units that comprises (a) afirst modular transportable unit comprising a natural gas-fired turbinegenerator with a maximum power output of between 1 and 40 MW, (b) asecond modular transportable unit comprising a HRSG for utilizing theexhaust gases of the turbine to generate steam and further comprising anemissions control unit to control NOx emissions, operably connected tothe turbine, and (c) a third transportable unit comprising an exhauststack unit with integrated emissions monitoring for NOx, operablyconnected to the HRSG; wherein the modular transportable units exist ina transportable form that is suitable for transport on an ordinaryroadway and in an assembled form that is fixed at the host site, andwherein the first, second and third modular transportable units eachcomprise at least one sensor and at least one actuator or actuatorsystem, wherein the sensors are configured to transmit inputs to acontrol system for controlling the cogeneration plant and the actuatorsare configured to receive an output from the control system, with nosubstantial modification from their configurations in the transportableunits to their configuration in the assembled units; and (ii) thecontrol system that comprises (a) a receiver system that receives inputsfrom the sensors in the modular units, signals from sensors in the hostfacility, signals from ambient environmental sensors, inputs frommarkets for natural gas, inputs from power markets, inputs from forecastsystems that comprise a weather forecast system and a price forecastsystem, and inputs from an interface through which the operator of thehost facility may enter changes in upcoming conditions at the hostfacility; (b) a processing system operably connected to the receiversystem for processing the inputs and determining outputs for modulatingthe activities of a plurality of actuators or actuator systems in one ormore of the modular units, wherein the plurality of actuators oractuator systems comprises the actuator or actuator systems in thefirst, third, and fourth modular transportable units, to achieve adesired result in the operation of the cogeneration plant based on theinputs and on the agreement; and (c) a transmitter system operablyconnected to the processor system for transmitting the outputs to theactuators or actuator systems; wherein the control system is at leastpartially Web-based and is configured to learn from an outcome of one ormore previous outputs and adjust the determining of future outputs basedon the learning, or on an override of an output or a plurality ofoverrides of outputs by an operator of the host facility, or acombination thereof.

In certain embodiments of the cogeneration system the first, second andthird modular transportable units are different. In certain embodiments,the cogeneration plant further comprises one or more additional modulartransportable units comprising a steam-driven compression refrigerationunit, operably connected to the HRSG. In certain embodiments thecogeneration system further comprises a sixth modular transportable unitcomprising a cooling tower, operably connected to the refrigeration unit

In certain embodiments the invention comprises steam turbine drivencompressors to provide mechanical work such as compression.

In certain embodiments the invention provides a method of manufacturinga modular cogeneration plant comprising (i) transporting a setcomprising a plurality of modular transportable units to a host sitecomprising a host facility that requires a thermal product and/ormechanical work product and, optionally, electrical power from thecogeneration plant, wherein (a) each of the modular transportable unitscontains one or more components, or parts of one or more components, ofthe cogeneration plant, and the components comprise a generator, a heattransfer unit, an air intake unit, and an exhaust unit; (b) the modulartransportable units exist in a transportable form and an assembled form;and (c) at least two of the modular transportable units comprise atleast one sensor and at least one actuator or actuator system, whereinthe sensors are configured to transmit inputs to a control system forcontrolling the cogeneration plant and the actuators are configured toreceive an output from the control system, with no substantialmodification from their configurations in the transportable units totheir configuration in the assembled units; and (ii) assembling themodules into a complete cogeneration plant wherein the modules areoperably connected to provide a functioning cogeneration plant under thecontrol of the control system, wherein the cogeneration plant isconfigured to provide the thermal product and/or mechanical work productand, optionally, electrical power to the host facility under anagreement between a provider of the cogeneration plant and a provider ofthe host facility.

In certain embodiments of the method, the components of the cogenerationplant contained in the modular transportable units further comprise arefrigeration unit and a cooling tower for the refrigeration unit; incertain embodiments the modular transportable units further comprisepumps.

In certain embodiments of the method the control system also receivesinputs from the host facility and from external sources and determinesoutputs for the actuators to achieve a desired result for the operationof the cogeneration plant over a period of time based on the inputs fromthe sensors, the host facility, and the external sources, and on theagreement.

In certain embodiments the set of modular transportable units comprisesat least 2, 3, 4, 5, 6, 7, or more than 7 modular transportable units.In certain embodiments, the number of modular transportable units isdetermined, at least in part, by the thermal and/or electrical poweragreed to be provided from the cogeneration plant to the facility.

In certain embodiments of the method, the cogeneration plant is capableof supplying 1-40 MW of electrical power to the host facility.

In certain embodiments, the method further comprises production of theagreement between the provider of the cogeneration plant and theprovider of the host facility e.g., where the agreement is produced atleast in part by selection of a plurality of financial modules by thehost facility from a menu of financial modules. In certain embodiments,the financial modules comprise a module for financing, a module for alower electrical demand limit, a module for an upper electrical demandlimit, a module for a lower thermal product demand limit, a module foran upper thermal product demand limit, a module for lower mechanicalwork product demand limit, a module for upper mechanical work productdemand limit, a module for average mechanical work product demand, amodule for average electrical demand, a module for average thermalproduct demand, or a price limit module, or any combination thereof.

In certain embodiments, the modular transportable units may be drawnfrom subsets of modular transportable unit and the set assembledaccording to the requirements of the agreement. Subsets of modulartransportable units are as described herein.

In certain embodiments of the method, the set of modular transportableunits comprises at least two of: a first module comprising an electricalgenerator; a second module comprising a heat recovery steam generator(HRSG); a third module comprising an exhaust stack; a fourth modulecomprising a component of a cooling tower; a fifth module comprising oneor more pumps; a sixth module comprising at least one air intake unit;and a seventh module comprising a thermal product carrier producer;wherein at least one of the modules is different from at least one ofthe other modules. In certain embodiments the set of modulartransportable units comprises at least three, at least four, at leastfive, at least six, or all seven of the abovementioned modules. Incertain embodiments, the first module and the second module are the samemodule. Other combinations of components, as described herein, may beused in other embodiments. In certain embodiments the electric generatorcomprises an internal combustion engine, a steam turbine, or a naturalgas turbine, e.g., in certain embodiments the electric generatorcomprises a natural gas turbine. In certain embodiments the HRSGcomprises a HRSG.

In certain embodiments of the method, the modular transportable unitscomprise at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16,17, 18, 19, 20, 22, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, or morethan 100 sensors to transmit inputs to the control system, wherein thesensors are configured to transmit the inputs with no substantialmodification from their configurations in the transportable units totheir configurations in the assembled units. The sensors may be anysensors as described herein, such as one or more sensors for atemperature, one or more sensors for a pressure, one or more sensors fora volume, one or more sensors for a first or a second state of one ormore units that can exist in the first or the second state, one or moresensors for a power generation level, one or more electrical sensors,one or more acoustical sensors, one or more optical sensors, one or morechemical detection sensors, one or more pH sensors, one or moreelectrical potential sensors, or one or more current sensors, or anycombination thereof. For example, in certain embodiments the sensorscomprise a HRSG exhaust temperature sensor, a steam flow rate sensor, agenerator output sensor, an exhaust temperature sensor, a thermalproduct carrier outlet temperature sensor, a thermal product carrierinlet temperature sensor, a thermal product carrier outlet flow ratesensor, a thermal product carrier inlet flow rate sensor, or at leastone of a NOx, SOx, CO, CO2, particulates, or O2 emission sensor, or anycombination thereof.

In certain embodiments of the method, the actuators or actuator systemscomprise 1, 2, 3, 4, 5, 6, or 7 of an actuator or actuator system forcontrolling a pre-cooler, an actuator or actuator system for controllingan electrical generator, e.g., a turbine, an actuator or actuator systemfor controlling a heat recovery steam generator, an actuator or actuatorsystem for controlling a thermal product carrier producer, an actuatoror actuator system for controlling a cooling tower, an actuator oractuator system for controlling one or more distribution pumps, and,optionally, an actuator or actuator system for controlling a thermalenergy storage product producer.

In certain embodiments, the inputs from the host facility comprise anelectrical energy demand, a thermal product carrier demand, a thermalproduct carrier flow rate, an air temperature, a thermal product carriertemperature, a fan rate, a humidity, a set point for an air temperaturewithin the host facility, or a set point for a thermal product carriertemperature, or any combination thereof. In certain embodiments, theexternal sources comprise sources about one or more market conditions,such as conditions for one or more local markets at the cogenerationplant location. In certain embodiments, the market conditions comprise1, 2, 3, 4, 5, 6, or all of a price for a fuel, e.g., natural gas, forthe cogeneration plant, a price for electrical energy exported from thecogeneration plant, a price for imported electrical energy to thecogeneration plant, a price for an incentive for the cogenerationplants, a price for a thermal product carrier produced by thecogeneration plant, a price for water for the cogeneration plant, and/ora price for a variable maintenance contract for the cogeneration plant.In certain embodiments, the incentives comprise one or more of anincentive for meeting a target.

In certain embodiments, the external sources of input to the controlsystem comprise sources of information about environmental conditions,such as a temperature, a humidity, a wind speed, a wind direction, atime of day, a day of the year, or an air pressure, or any combinationthereof.

In certain embodiments, the receiver further receives input indicating adesired future modulation in the conditions of the host facility forexample an input indicating a desired future modulation is inputted froman interface for interaction between the system and an operator of thehost facility.

In certain embodiments of the method the control system is configured toforecast determines a change or no change for one or more of the outputsfor one or more of the actuators based at least in part on a forecaststep, such as a forecast step that forecasts a future value or range ofvalues for 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10 of a fuelprice, an electricity export price, an electricity import price, anambient environmental condition, an emissions limit, an incentive forthe cogeneration plant, a price for a thermal product, a price forwater, an electrical demand from the host facility, a thermal productdemand from the host facility. In certain embodiments, the forecast stepforecasts a probability for the occurrence of one or more of the futurevalues or range of values. Further embodiments of forecast steps are asdescribed herein.

In certain embodiments, the control system the control system adjuststhe determining of a change or no change in the one or more outputs onone or more of outcomes from one or more past outputs to thecogeneration plant. This may be done in any manner as described herein.

In certain embodiments of the method, the control system comprises asubcontroller for utilizing a thermal product carrier distributionsystem and temperature maintenance system that are at least partiallylocated in the host facility to both distribute a thermal productcarrier and to store thermal energy. Inputs and outputs for thesubcontroller and processing methods are as described elsewhere herein.

In certain embodiments of the method, the cogeneration plant isconfigured to operate over a three month, four month, five month, sixmonth, 8 month, 10 month, or 12 month period at an average efficiency ofat least 80, 81, 82, 83, 84, 85, 87, 88, 89, 90, 91, 92, 93, 94, or 95%when the host facility electrical power demand and/or the host facilitythermal product demand vary by at least an average of 5, 6, 7, 8, 9, 10,11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 25, 27, 30, 32, 35, 37, 40,45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95% daily during the period.

In certain embodiments of the method, the control system is at leastpartially Web-based. In certain embodiments the input is transmittedfrom at least one of the sensors to the control system wirelessly, forexample all of the inputs are transmitted wirelessly. In certainembodiments, one or more of the outputs is transmitted from the controlsystem to an actuator wirelessly, for example, all of the outputs aretransmitted wirelessly.

In certain embodiments of the method, a cogeneration network isestablished including installing a plurality of cogeneration systemsaccording to any of the embodiments above or combination of embodiments.In certain embodiments, the optimization of the operation of acogeneration plant, or a plurality of cogeneration plants, or all of thecogeneration plants, within the network is designed to help optimize theoperation of the network, such as to optimize a profit and/or energyefficiency for the network.

In certain embodiments the invention provides a cogeneration networkcomprising (i) a plurality of cogeneration systems, wherein eachcogeneration system comprises a cogeneration plant operably connected toa host facility that receives a thermal product and, optionally,electrical power from the cogeneration plant, and wherein at least oneof the cogeneration plants comprises a plurality of operably connectedmodular transportable units; and (ii) a common controller for optimizingthe operation and/or maintenance of the cogeneration network that isoperably connected to the plurality of cogeneration systems wherein thecommon controller (a) receives inputs from a plurality of sensors in ornear each of the plurality of cogeneration systems; (b) processes theinputs to determine a plurality of outputs, and (c) transmits theoutputs to a plurality of actuators in the plurality of cogenerationsystems, whereby the operation of the network of cogeneration systems isoptimized.

In certain embodiments, the network comprises at least 2, 3, 4, 5, 6, 7,8, 9, 10 or more than 10 cogeneration systems.

In certain embodiments, at least 2, 3, 4, 5, 6, 7, 8, 9, 10 or more than10 of the cogeneration systems comprise a plurality of operablyconnected modular transportable units. The units may be any suitableunits as described herein.

In certain embodiments, the sensors comprise sensors in the cogenerationplants, sensors in the host facilities, sensors for the environment ator near one or more of the cogeneration plants and/or host facilities,or sensors for operable connections between one or more of thecogeneration plants and it host facility, or any combination thereof. Incertain of these embodiments, the sensors for the environment at or nearone or more of the cogeneration plants comprise sensors for temperature,humidity, wind speed, wind direction, time of day, day of the year, airpressure, or any combination thereof.

In certain embodiments, the common controller further receives inputfrom one or more of the host facilities in one or more of thecogeneration systems, wherein the input comprises an electrical energydemand, a mechanical work product demand, a thermal product demand, athermal product carrier flow rate, an air temperature, a thermal productcarrier temperature, a fan rate, a humidity, a set point for an airtemperature, a set point for a thermal product carrier temperature, orany combination thereof, or any other input as described herein.

In certain embodiment, the common controller further receives inputsfrom indicators of market conditions. In certain embodiments, the inputsof market conditions comprise inputs for local markets at the one ormore cogeneration systems. In certain embodiments, the market conditionscomprise 1, 2, 3, 4, 5 or all of a price for a fuel for at least 1, 2,3, 4, 5 or more than 5 of the cogeneration plants, a price forelectrical energy exported from for at least 1, 2, 3, 4, 5 or more than5 of the cogeneration plants, a price for imported electrical energy toat least 1, 2, 3, 4, 5 or more than 5 of the cogeneration plants, aprice for an incentive for at least 1, 2, 3, 4, 5 or more than 5 of thecogeneration plants, a price for a thermal product produced by for atleast 1, 2, 3, 4, 5 or more than 5 of the cogeneration plants, a pricefor water for at least 1, 2, 3, 4, 5 or more than 5 of the cogenerationplants, and/or a price for a variable maintenance price for at least 1,2, 3, 4, 5 or more than 5 of the cogeneration plants.

In certain embodiments of the network, the common controller receivesinputs from at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 50,100, 150, 200, 250, 500, 1000, or more than 1000 sensors, for examplemore than 5000 sensors. The sensors in some embodiments are located inat least 2, 3, 4, 5, 6, 7, 8, 9, 10 or more than 10 cogenerationsystems. The sensors may be any type of sensor as described herein. Incertain embodiments, the sensors in one or more of the cogenerationsystems comprise sensors for 2, 3, 4, 5, 6, 7, 8, or more than 8 ofsensors for sensing a HRSG exhaust temperature, a steam flow rate, agenerator output, an exhaust temperature, a thermal product carrieroutlet temperature, a thermal product carrier inlet temperature, athermal product carrier outlet flow rate, a thermal product carrierinlet flow rate, at least one of a NOx, SOx, CO, CO2, particulate, or O2emission.

In certain embodiments of the network, the actuators or actuator systemsin a cogeneration plant of the system comprise 1, 2, 3, 4, 5, 6, or 7 ofan actuator or actuator system for controlling a pre-cooler, an actuatoror actuator system for controlling a turbine, an actuator or actuatorsystem for controlling a heat recovery steam generator, an actuator oractuator system for controlling a thermal product carrier producer, anactuator or actuator system for controlling a cooling tower, an actuatoror actuator system for controlling one or more distribution pumps, and,optionally, an actuator or actuator system for controlling a thermalenergy storage product producer.

In certain embodiments of the network, the controller transmits outputsto at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 50, 100, 150,200, 250, 500, 1000, or more than 1000 actuators in the plurality ofcogeneration plants of the network. In certain embodiments, thecontroller transmits outputs to an average of at least 2, 3, 4, 5, 6, 7,8, 9, 10, 15, 20, 25, 30, or more than 30 actuators per cogenerationsystem.

In certain embodiments of the network, the common controller furtherreceives input indicating a desired future modulation in a condition ofat least 1, 2, 3, 4, 5, 7, 10, 12, or more than 12 host facilities, suchas a desired future modulation that is inputted from an interface forinteraction between the system and an operator of the host facility.

In certain embodiments of the network, the modular transportable unitsof one of the cogeneration plants comprise a modular transportable unitcomprising an electrical generator, a modular transportable unitcomprising a heat recovery steam generator (HRSG), a modulartransportable unit comprising a thermal product carrier producer, amodular transportable unit comprising a cooling tower, a modulartransportable unit comprising an exhaust stack, or a modulartransportable unit comprising a an air intake unit, or any combinationthereof.

In certain embodiments of the network, at least two of the cogenerationplants comprise modular transportable units wherein for each of the twoplants the modular transportable units comprise a modular transportableunit comprising an electrical generator, a modular transportable unitcomprising a heat recovery steam generator (HRSG), a modulartransportable unit comprising a thermal product carrier producer, amodular transportable unit comprising a cooling tower, a modulartransportable unit comprising an exhaust stack, or a modulartransportable unit comprising a an air intake unit, or any combinationthereof.

In certain embodiments of the network, at least two of the cogenerationplants comprise modular transportable units wherein for each of the twoplants the modular transportable units comprise at least two of amodular transportable unit comprising an electrical generator, a modulartransportable unit comprising a heat recovery steam generator (HRSG), amodular transportable unit comprising a thermal product carrierproducer, a modular transportable unit comprising a cooling tower, amodular transportable unit comprising an exhaust stack, or a modulartransportable unit comprising a an air intake unit, or any combinationthereof.

In certain embodiments of the network, at least two of the cogenerationplants comprise modular transportable units wherein for each of the twoplants the modular transportable units comprise at least three of amodular transportable unit comprising an electrical generator, a modulartransportable unit comprising a heat recovery steam generator (HRSG), amodular transportable unit comprising a thermal product carrierproducer, a modular transportable unit comprising a cooling tower, amodular transportable unit comprising an exhaust stack, or a modulartransportable unit comprising a an air intake unit, or any combinationthereof.

In certain embodiments of the network the processing of step (ii)(b)comprises a forecast step, e.g., as described herein. In certainembodiments, the forecast step forecasts a future value or range ofvalues for 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10 of a fuelprice, an electricity export price, an electricity import price, anambient environmental condition, an emissions limit, an incentive forthe cogeneration plant, a price for a thermal product, a price forwater, an electrical demand from a host facility, a thermal productdemand from a host facility, wherein the future value is a value for atleast one of the cogeneration systems. In certain embodiments, thefuture value or range of values is a value or range of values for atleast 2, 3, 4, 5, 6, 7 8, 9, 10, 12, 15, 20, or more than 20 of thecogeneration systems. In certain embodiments, the forecast stepforecasts a probability for the occurrence of one or more of the futurevalues or range of values. In certain embodiments, the processing stepcomprises determining a change in one or more set points for one or morethe actuators based at least in part on one or more of the forecastvalues or range of values.

In certain embodiments, the control system adjusts the processing stepbased on one or more of the results of a previous output, such as aresult stored in the data storage unit, to improve the function of thenetwork in the future. Any suitable embodiment of such learning, asdescribed herein, may be used.

In certain embodiments the control system establishes a profile for acogeneration plant and/or a cogeneration system in the network. Incertain embodiments, the control system groups a plurality ofcogeneration systems into a peer group according to the profiles oftheir cogeneration plants and/or cogeneration systems. In certainembodiments, as described herein, the control system adjusts a profilefor one or more cogeneration plants and/or cogeneration systems based onexperiments, experience, operator overrides, and other experiences asdescribed elsewhere herein. Profiles, peer groups, and development ofprofiles are described more fully herein.

In certain embodiments, the optimization of the operation of the networkoptimizes the profit of the network over a desired time period. The timeperiod may be any time period for the optimization of a profit asdescribed herein. In certain embodiments, the time period is an hour, aday, a week, a month, a quarter, two quarters, three quarters, or ayear.

In certain embodiments of the common controller comprises asubcontroller for utilizing a thermal product carrier distributionsystem as a thermal energy storage system in at least one of the hostfacilities to both distribute a thermal product carrier and to storethermal energy. Such subcontrollers may be any type as described herein,suitably modified for inclusion in a common controller for a network. Incertain embodiments, the subcontroller for utilizing a thermal productcarrier distribution system as a thermal storage system in at least 2,3, 4, 5, or more than 5 of the host facilities to both distribute athermal product carrier and to store thermal energy. In certainembodiments, the subcontroller receives inputs for one, 2, 3, 4, 5, 6,7, 9, 10 or more than 10 air temperatures within a particular hostfacility, inputs for set points for one, 2, 3, 4, 5, 6, 7, 9, 10 or morethan 10 air temperatures within the particular facility, and inputs forone, 2, 3, 4, 5, 6, 7, 9, 10 or more than 10 fan rates within theparticular host facility. In certain embodiments, the subcontrollerfurther receives inputs from a heat product producer in a particularcogeneration plant comprising 1, 2, 3, 4, 5, 6, 7, 8, 9 or all of apercent load of the thermal product carrier producer, an absolute loadof a thermal product carrier producer, an operation state of a thermalproduct carrier producer, an outlet flow rate for a thermal productcarrier produced by the thermal product carrier producer, an inlet flowrate for the thermal product carrier, an outlet temperature for athermal product carrier produced by the thermal product carrierproducer, and/or an inlet temperature foe a thermal product carrierproduced by the thermal product carrier producer. In certainembodiments, the subcontroller determines whether or not a set point forone or more of the process units that corresponds to one or more of theinputs described above should be altered. In certain embodiments, thesubcontroller determines the one or more set points based on keeping thethermal product carrier producer or thermal product carrier producersoperating within a range of percentages of maximum operation. In certainembodiments, the range of percentages is a range around an optimumefficiency operating percentage for the thermal product carrier produceror thermal product carrier producers. In certain embodiments, the upperlimit of the range is within 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,14, 15, 16, 17, 18, 19, 20, 22, or 25% of the optimum efficiencypercentage and the lower limit of the range is within 1, 2, 3, 4, 5, 6,7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, or 25% of theoptimum efficiency percentage. In certain embodiments, the subcontrollerfurther determines set points for 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12,13, 14, 15, 16, 17, 18, 19, 20, or more than 20 fan rates within thehost facility, based at least in part on the range of percentages.

In certain embodiments of the network, the common controller is at leastpartially Web-based. In certain embodiments of the network some or allof the inputs, the outputs, or both the inputs and the outputs aretransmitted wirelessly.

In certain embodiments the invention provides a system comprising (i) afirst cogeneration plant that produces electrical power and a firstthermal or mechanical work product, operably connected to a firstfacility that utilizes at least a portion of the electrical power fromthe first cogeneration plant and to a second facility that utilizes atleast a portion of the first thermal or mechanical work product, whereinthe first facility and the second facility may be the same or different;(ii) a second cogeneration plant that produces electrical power and asecond thermal or mechanical work product, operably connected to a thirdfacility that utilizes at least a portion of the electrical power fromthe second cogeneration plant and to a fourth facility that utilizes atleast a portion of the second thermal or mechanical work product,wherein the third facility and the fourth facility may be the same ordifferent; and (iii) a control system operably connected to the firstand second cogeneration plants and the first, second, third, and fourthfacilities, wherein the control system is configured to (a) receiveinputs from the first and second cogeneration plants, the first, second,third, and fourth facilities, and indicators of expenses or potentialexpenses for the first and second cogeneration plants, indicators ofrevenues or potential revenues for the first and second cogenerationplants, or for any combination thereof; (b) calculate a setpoint for acontroller in the first cogeneration plant, the second cogenerationplant, the first facility, the second facility, the third facility, orthe fourth facility, or any combination thereof, wherein the setpoint isbased on the inputs, and is calculated to optimize a combined profit forthe first and second cogeneration plants in a time period; and (c) ifthe setpoint in (ii) is different from the current setpoint for thecontroller, sending output to the controller to modulate the activity ofthe controller to approach the setpoint.

In certain embodiments the invention provides a network of cogenerationsystems comprising a first cogeneration system and a second cogenerationsystem, wherein the first cogeneration system includes a firstcogeneration plant that includes a plurality of modular transportableunits that are operably connected and a first host facility thatreceives electric power and/or a thermal product from the firstcogeneration plant under a first agreement, and the second cogenerationsystem includes a second cogeneration plant that includes a plurality ofmodular transportable units that are operably connected and a secondhost facility that receives electric power and/or a thermal product fromthe second cogeneration plant under a second agreement, and a commoncontroller that comprises a receiving system for receiving inputs from aplurality of sensors in a plurality of the modular transportable unitsin the first cogeneration plant and the second cogeneration plant, fromthe host facilities, and from external sources, a processing system forprocessing the inputs to achieve an optimal operating result for thenetwork while meeting an obligation in the first agreement and anobligation in the second agreement, and a transmitting system fortransmitting a plurality of outputs to a plurality of actuators in aplurality of the modular transportable units in the first cogenerationplant and the second cogeneration plant so as to achieve the optimaloperating result for the network.

In certain embodiments the invention provides a cogeneration plantoperably connected to a host facility that has a variable thermal and/ormechanical work product demand and a variable electrical power demandand that receives a thermal and/or mechanical work product andelectrical energy from the cogeneration plant according to the variabledemands, wherein the cogeneration plant is configured to operate over athree month period at an average efficiency of at least 80% when thehost facility electrical power demand and/or the host facility thermalproduct demand vary by at least an average of 5% daily.

In certain embodiments of the cogeneration plant the average efficiencyis at least 81, 82, 83, 84, 85, 86, 87, 88, or 90%. In certainembodiments, the host facility electrical power demand and/or the hostfacility thermal or mechanical work product demand vary by at least anaverage of 6, 7, 8 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21,22, 25, 27, 30, 32, 35, 371, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90,95, or 100% daily.

In certain embodiments the invention provides a system for storingthermal energy and distributing a thermal product carrier comprising (i)a thermal product carrier producer that produces a thermal productcarrier; (ii) a distribution system that distributes the thermal productcarrier to a facility that uses the thermal product carrier according toa need for the thermal product; and (iii) a controller operablyconnected to the distribution system and to the thermal product carrierproducer, wherein the controller is configured to modulate the operationof a first part of the distribution system and a second part of thedistribution system based on inputs from the facility and from thedistribution system, such that that the energy required to provide thethermal product carrier to the facility that uses it according to theneed for a thermal product is optimized.

In certain embodiments the invention provides a method for storingchilling potential and distributing chilling potential comprising (i)generating a chilled water product with a refrigeration unit in acogeneration plant; (ii) transporting the chilled water product to afacility that requires a time-varying amount of chilling potential;(iii) distributing the chilled water product to one or more areas in thefacility; (iv) running the chilled water product through a coil in theone or more areas of the facility; and (v) moving air in the one or moreareas across the coil with a variable-speed fan; (vii) controlling thespeed of the fan according to the chilling needs of the area, such thatduring low chilling need periods the fan runs slowly or is turned off,and during high chilling need periods the fan runs more quickly, andsuch that the chilled water product in the coil varies in temperature,thus storing chilling potential during low demand times and releasing itduring high demand times.

In certain embodiments the invention provides a method of peak shiftinga thermal product carrier producer, e.g., refrigeration unit, loadcomprising storing and releasing thermal energy from the thermal productproducer in a distribution system for the thermal product.

In certain embodiments the invention provides a system for storingchilling potential and distributing chilling potential comprising (i) arefrigeration unit that produces a chilled water product, wherein therefrigeration unit operates continuously at between 60-100% load atleast 90% of the time; (ii) a refrigeration unit exit conduit thattransports the chilled water product to a facility in need of chilledwater product, wherein the conduit is operably connected to therefrigeration unit and to the facility; (iii) a distribution systemwithin the facility, operably connected to the refrigeration unit exitconduit, that distributes the chilled water product to one or more areasin the facility in need of chilling; (iv) a heat transfer systemoperably connected to the distribution system, comprising aheat-conductive chilled water product conduit and a fan to move airacross the heat-conductive chilled water conduit, for transferring heatfrom the area in need of chilling to the chilled water product, toproduce a desired degree of chilling in the area, wherein the fan is avariable-speed fan; and (v) a collection system operably connected tothe heat transfer system for collecting chilled water product exitingthe heat transfer system; (vi) a refrigeration unit return conduitoperably connected to the collection system and to the refrigerationunit, that transports chilled water product from the facility to therefrigeration unit; and (vii) a control system operably connected to thefacility, the refrigeration unit, and the fans, wherein the controlsystem is configured to (a) receive inputs from sensors that detecttemperature in the facility, temperature of the chilled water product atvarious points in the system, load of the refrigeration unit, flow ratesof the chilled water product at various points in the system, and fanspeeds for the fans in the facility, and inputs from indicators ofdesired temperature in one or more areas of the facility; (b) calculatea fan rate, a flow rate for chilled water product, a load level for therefrigeration unit, a vent level for a thermal vent, or any combinationthereof; and (c) calculate a setpoint for a fan, a chilled water productvalve, a thermal vent valve, a refrigeration unit load controller, orany combination thereof, based on the calculation of (b); and (d) outputa signal or signals to adjust a fan speed, a chilled water product valveposition, or a load level for a refrigeration unit load controller, orany combination thereof.

While preferable embodiments of the present invention have been shownand described herein, it will be obvious to those skilled in the artthat such embodiments are provided by way of example only. Numerousvariations, changes, and substitutions will now occur to those skilledin the art without departing from the invention. It should be understoodthat different aspects of the invention can be appreciated individually,collectively, or in combination with each other. It should be understoodthat various alternatives to the embodiments of the invention describedherein may be employed in practicing the invention. It is intended thatthe following claims define the scope of the invention and that methodsand structures within the scope of these claims and their equivalents becovered thereby.

What is claimed is:
 1. A cogeneration network comprising (i) a pluralityof cogeneration systems comprising a first and second cogenerationsystem, wherein the first and second cogeneration systems are different,wherein each cogeneration system comprises a cogeneration plant operablyconnected to a host facility that receives a thermal product and/ormechanical work product and, optionally, electrical power from thecogeneration plant; and (ii) a common controller that is operablyconnected to the plurality of cogeneration systems wherein the commoncontroller (a) receives inputs from a plurality of sensors in or neareach of the plurality of cogeneration systems; (b) processes the inputsto determine a plurality of outputs, and (c) transmits the outputs to aplurality of actuators in the plurality of cogeneration systems; andwherein the common controller is configured to learn by periodicallyupdating a profile for a first cogeneration system in the network,wherein the profile for the first cogeneration system comprises at leastone performance curve for at least one of a unit comprising one or moreprime mover/generators, one or more heat transfer systems, one or morethermal product carrier producers, or one or more cooling towers, andwherein the performance curves are not off-the-shelf curves provided bymanufacturers of the components but comprise curves produced after thecommissioning of the first cogeneration system, during operation of thesystem over time, and applying the profile to a second cogenerationsystem in the network.
 2. The cogeneration network of claim 1 whereinthe controller is configured to learn from an outcome of one or moreprevious outputs and adjust the determining of future outputs based onthe learning, or on an override of an output or a plurality of overridesof outputs by an operator of the host facility, or a combinationthereof.
 3. The cogeneration network of claim 1 wherein the controlleris configured to learn by changing one or more outputs directed at asystem or subsystem of one or more components of at least onecogeneration system of the network, during operation of the system, tobe different from the output of a current controller, evaluating theresults to determine if the change in output produced a better or worseresult than would have been expected from the current controller, andadjusting algorithms used by the processing system according to theresults.
 4. The cogeneration network of claim 3 wherein the algorithmsare adjusted to apply to cogeneration systems in the network that werenot subject to the changing of one or more outputs.
 5. A controller fora network comprising a plurality of cogeneration systems, wherein thecontroller is configured to (i) receive inputs from a plurality ofsensors in or near each of the plurality of cogeneration systems; (ii)process the inputs to determine a plurality of outputs, and (iii)transmit the outputs to a plurality of actuators in the plurality ofcogeneration systems; wherein the common controller is configured tolearn, and wherein said learning comprises (a) learning from an outcomeof one or more previous outputs and adjusting the determining of futureoutputs based on the learning, or on an override of an output or aplurality of overrides of outputs by an operator of the host facility,or a combination thereof (b) periodically updating a profile for a firstcogeneration system in the network, wherein the profile for the firstcogeneration system comprises at least one performance curve for atleast one of a unit comprising one or more prime mover/generators, oneor more heat transfer systems, one or more thermal product carrierproducers, or one or more cooling towers, and wherein the performancecurves are not off-the-shelf curves provided by manufacturers of thecomponents but comprise curves produced after the commissioning of thefirst cogeneration system, during operation of the system over time, andapplying the profile to a second cogeneration system in the network; and(c) by changing one or more outputs directed at a system or subsystem ofone or more components of at least one cogeneration system of thenetwork, during operation of the system, to be different from the outputof a current controller, evaluating the results to determine if thechange in output produced a better or worse result than would have beenexpected from the current controller, and adjusting algorithms used bythe processing system according to the results.
 6. The controller ofclaim 5 wherein said learning comprises at least one of (i) learningfrom an outcome of one or more previous outputs and adjusting thedetermining of future outputs based on the learning, or on an overrideof an output or a plurality of overrides of outputs by an operator ofthe host facility, or a combination thereof; (ii) periodically updatinga profile for a first cogeneration system in the network, wherein theprofile for the first cogeneration system comprises at least oneperformance curve for at least one of a unit comprising one or moreprime mover/generators, one or more heat transfer systems, one or morethermal product carrier producers, or one or more cooling towers, andwherein the performance curves are not off-the-shelf curves provided bymanufacturers of the components but comprise curves produced after thecommissioning of the first cogeneration system, during operation of thesystem over time, and applying the profile to a second cogenerationsystem in the network; or (iii) by changing one or more outputs directedat a system or subsystem of one or more components of at least onecogeneration system of the network, during operation of the system, tobe different from the output of a current controller, evaluating theresults to determine if the change in output produced a better or worseresult than would have been expected from the current controller, andadjusting algorithms used by the processing system according to theresults.
 7. The controller of claim 5 wherein said learning comprises atleast two of (i) learning from an outcome of one or more previousoutputs and adjusting the determining of future outputs based on thelearning, or on an override of an output or a plurality of overrides ofoutputs by an operator of the host facility, or a combination thereof;(ii) periodically updating a profile for a first cogeneration system inthe network, wherein the profile for the first cogeneration systemcomprises at least one performance curve for at least one of a unitcomprising one or more prime mover/generators, one or more heat transfersystems, one or more thermal product carrier producers, or one or morecooling towers, and wherein the performance curves are not off-the-shelfcurves provided by manufacturers of the components but comprise curvesproduced after the commissioning of the first cogeneration system,during operation of the system over time, and applying the profile to asecond cogeneration system in the network; or (iii) by changing one ormore outputs directed at a system or subsystem of one or more componentsof at least one cogeneration system of the network, during operation ofthe system, to be different from the output of a current controller,evaluating the results to determine if the change in output produced abetter or worse result than would have been expected from the currentcontroller, and adjusting algorithms used by the processing systemaccording to the results.
 8. The network of claim 1 wherein thecontroller is configured so that the processing of step (ii)(b)comprises a forecast step, and wherein the forecast step forecasts afuture value or range of values, or a probability of a future value orrange of values, for a fuel price, an electricity export price, anelectricity import price, an ambient environmental condition, anemissions limit, an incentive for the cogeneration plant, a price for ademand response action, a price for a thermal product, a price forwater, an electrical demand from a host facility, or a thermal productdemand from a host facility, wherein the future value or range of futurevalues, or probability of a future value or range of future values, is avalue or range of values or probability of a value or range of valuesfor at least one of the cogeneration systems; and wherein the controlleris configured so that the processing step of ii(b) may comprisedetermining a change in one or more set points for one or more theactuators based at least in part on one or more of the forecast valuesor range of values.
 9. The network of claim 8 wherein the commoncontroller further comprises a data storage unit for storing a value fora timing and/or result that occurs after the change in the one or moreset points, and wherein the controller is configured to adjust theprocessing step based on one or more of the results of a previousoutput, such as a result stored in the data storage unit, to improve thefunction of the network in the future.
 10. The network of claim 1comprising at least 3 different cogeneration systems.
 11. The network ofclaim 1 comprising at least 10 different cogeneration systems.
 12. Thenetwork of claim 1 wherein the common controller is configured to learnin a process that comprises learning from an outcome of an output at thefirst cogeneration plant in the plurality of cogeneration plants andapplying the learning to the determining step for an output for thesecond cogeneration plant in the plurality of cogeneration plants. 13.The network of claim 1 wherein the control system learns by artificialintelligence, machine learning, or evolutionary algorithms.
 14. Thenetwork of claim 1 wherein the control system establishes a profile foreach of the first and second cogeneration systems and groups the firstand second cogeneration systems into a peer group based on theirprofiles.
 15. The network of claim 1 wherein the common controllerfurther receives inputs from indicators of market conditions for thefirst and the second cogeneration systems, wherein the market conditionscomprise at least one of a price for a fuel for the first and/or secondcogeneration systems; a price for electrical energy exported from thefirst and/or second cogeneration systems; a price for importedelectrical energy to the first and/or second cogeneration systems; aprice for an incentive for the first and/or second cogeneration systems;a price for a thermal product produced by the first and/or secondcogeneration systems; a price for water for the first and/or secondcogeneration systems; , or a variable maintenance price for at the firstand/or second cogeneration systems.
 16. The network of claim 1 whereinthe common controller further receives inputs from indicators of marketconditions for the first and the second cogeneration systems, whereinthe market conditions comprise at least two of a price for a fuel forthe first and/or second cogeneration systems; a price for electricalenergy exported from the first and/or second cogeneration systems; aprice for imported electrical energy to the first and/or secondcogeneration systems; a price for an incentive for the first and/orsecond cogeneration systems; a price for a thermal product produced bythe first and/or second cogeneration systems; a price for water for thefirst and/or second cogeneration systems; , or a variable maintenanceprice for at the first and/or second cogeneration systems.
 17. Thenetwork of claim 1 wherein the common controller receives inputindicating a desired future modulation in a condition of at least one ofthe host facilities of the first or second cogeneration systems.